Dissolved air de-bonding of a tissue sheet

1. A method of making a tissue paper having a geometric mean tensile (GMT) in a range between about 500 and about 5,000 g/3 in. and a caliper in a range between about 50 and about 350 mils/8 sheets, the method comprising:

compressing a water-soluble gas with a compressor to form a compressed water-soluble gas;

mixing an aqueous solution and a fiber slurry comprising cellulosic fibers under a super-atmospheric pressure in a contained environment in the presence of a compressed water-soluble gas to form a dilute dissolved gas-impregnated fiber slurry comprising dissolved gas-impregnated fibers;

discharging the dilute dissolved gas-impregnated fiber slurry from the contained environment directly onto a foraminous support at a lower pressure to form a nascent web, the lower pressure being a pressure less than the super-atmospheric pressure; and

drying the nascent web to expand, separate, or both expand and separate the dissolved gas-impregnated fibers to form the tissue paper;

wherein the tissue paper comprises less than 4 pounds per ton of a chemical debonder.

2. The method of claim 1 , wherein the dilute dissolved gas-impregnated fiber slurry is formed by either:

exposing the aqueous solution to the compressed water-soluble gas under the super atmospheric pressure in the contained environment to form a dissolved gas-impregnated solution, and then mixing the dissolved gas-impregnated solution with the fiber slurry in the contained environment to form the dilute dissolved gas-impregnated fiber slurry;

exposing the fiber slurry to the compressed water-soluble gas under the super-atmospheric pressure in the contained environment to form a dissolved gas-impregnated fiber slurry, and then mixing the dissolved gas-impregnated fiber slurry with the aqueous solution to form the dilute dissolved gas-impregnated fiber slurry; or

forming a dilute fiber slurry, and then exposing the dilute fiber slurry to the compressed water-soluble gas under the super-atmospheric pressure in the contained environment to form the dilute dissolved gas-impregnated fiber slurry.

3. The method of claim 2 , wherein the lower pressure is about atmospheric pressure.

4. The method of claim 2 , wherein the lower pressure is less than about atmospheric pressure.

5. The method of claim 2 , wherein the gas is nitrogen gas, oxygen gas, argon gas, or any combination thereof.

6. The method of claim 2 , wherein the gas is air.

7. The method of claim 2 , wherein the super-atmospheric pressure is at least about 20 psig.

8. The method of claim 2 , wherein the cellulosic fibers are hardwood kraft fibers, softwood kraft fibers, hardwood sulfite fibers, softwood sulfite fibers, recycled fibers, mechanical fibers, or any combination thereof.

9. The method of claim 2 , wherein drying is air drying.

10. The method of claim 2 , wherein drying is vacuum air drying.

11. The method of claim 2 , wherein drying is through-air drying (TAD).

12. The method of claim 11 , wherein TAD is conducted at an absolute pressure sufficient to further separate fibers within the nascent web.

13. The method of claim 2 , wherein drying occurs on the surface of a Yankee dryer.

14. The method of claim 2 , wherein drying is conducted at a temperature sufficient to further separate fibers within the partially de-gassed fibers of the nascent web.

15. The method of claim 2 , wherein drying is conducted at an absolute pressure sufficient to further separate fibers within the nascent web.

16. The method of claim 2 , further comprising molding the nascent web at an absolute pressure sufficient to further separate fibers within the nascent web.

17. The method of claim 2 , further comprising transferring the nascent web to a dryer and wherein transferring is conducted at an absolute pressure sufficient to further separate fibers within the nascent web.

18. The method of claim 2 , further comprising pressing the nascent web prior to drying, wherein further separation of fibers within the nascent web occurs.

19. A method of making a tissue paper having a geometric mean tensile (GMT) in a range between about 500 and about 2,500 g/3 in. and a caliper of at least about 50 mils/8 sheets, the method comprising:

compressing a water-soluble gas with a compressor to form a compressed water-soluble gas;

exposing an aqueous solution to the compressed water-soluble gas under a super-atmospheric pressure in a contained environment to form a dissolved gas-impregnated solution;

mixing the dissolved gas-impregnated solution with a fiber slurry comprising cellulosic fibers in the contained environment to form a dilute dissolved gas-impregnated fiber slurry comprising dissolved dissolved gas-impregnated fibers;

discharging the dilute dissolved gas-impregnated fiber slurry from the contained environment directly onto a foraminous support at atmospheric pressure to form a nascent web; and

drying the nascent web to expand, separate, or both expand and separate the dissolved gas-impregnated fibers to form the tissue paper;

wherein the tissue paper comprises less than 4 pounds per ton of a chemical debonder.

20. The method of claim 19 , wherein the gas is nitrogen gas, oxygen gas, argon gas, or any combination thereof.

21. The method of claim 19 , wherein the gas is air.

22. The method of claim 19 , wherein the super-atmospheric pressure is at least about 20 psig.

23. The method of claim 19 , wherein the cellulosic fibers are hardwood kraft fibers, softwood kraft fibers, hardwood sulfite fibers, softwood sulfite fibers, recycled fibers, mechanical fibers, or any combination thereof.

24. The method of claim 19 , wherein drying is conducted at a temperature sufficient to further separate fibers of the nascent web.

25. The method of claim 19 , further comprising pressing the nascent web prior to drying to further separate fibers of the nascent web.