ABSORBENT TISSUE PAPER PRODUCT, METHOD AND APPARATUS FOR PRODUCING THE SAME

Abstract

The present disclosure relates to an absorbent tissue paper product comprising one ply being an essentially continuous ply of fibrous structure having a first side and a second side, the first side having a surface roughness arithmetical mean height (Sa1), and said second side having a surface roughness arithmetical mean height (Sa2). Said ply has a micro-embossed structure and a difference between the surface roughness arithmetical mean heights of the first side and the second side is 7 μm or less (|Sa1−Sa2|≤7 μm), and said ply having a bulk of at least 7.5 cm3/g. The disclosure also relates to a method and an apparatus for producing such an absorbent tissue paper product.

Claims

1. An absorbent tissue paper product comprising one ply being an essentially continuous ply of a fibrous structure having a first side and a second side, said first side having a surface roughness arithmetical mean height (Sa1), and said second side having a surface roughness arithmetical mean height (Sa2), said ply being a structured tissue paper ply, wherein said ply has a micro-embossed structure and a difference between the surface roughness arithmetical mean heights of the first side and the second side is 7 μm or less (|Sa1−Sa2|≤7 μm), and in that said ply has a bulk of at least 7.5 cm.sup.3/g.

2. An absorbent tissue paper product according to claim 1, wherein said first side has a developed interfacial area ratio (Sdr1) and said second side has a developed interfacial area ratio (Sdr2), and a difference between the developed interfacial area ratios of the first side and the second side is 2% or less (|Sdr1−Sdr2|≤2%).

3. An absorbent tissue paper product according to claim 1, wherein said ply has a basis weight in the range of 18 to 60 gsm.

4. An absorbent tissue paper product according to claim 1, wherein said ply has a thickness in the range of 0.1 to 0.5 mm.

5. An absorbent tissue paper product according to claim 1, wherein said ply has a CD wet strength in the range of 40 to 120 N/m.

6. An absorbent tissue paper product according to claim 1, wherein said ply has an absorption capacity of at least 7 g/g, preferably at least 9 g/g.

7. An absorbent tissue paper product according to claim 1, wherein said micro-embossed structure comprises from 30 to 80 dots/cm.sup.2.

8. An absorbent tissue paper product according to claim 7, wherein said micro-embossed structure is an Accurate Bulk Embossed (ABE) structure.

9. An absorbent tissue paper product according to claim 7, wherein said micro-embossed structure is a Matched Steel embossed structure.

10. (canceled)

11. An absorbent tissue paper product according to claim 1, wherein said ply is a TAD technology produced ply.

12. An absorbent tissue paper product according to claim 1, wherein said ply is an ATMOS® technology produced ply.

13. An absorbent tissue paper product according to claim 1 consisting of said ply.

14. Method for producing an absorbent tissue paper product comprising the steps of; providing one essentially continuous ply of a fibrous structure having a first side and a second side, said ply being a structured tissue paper ply, and processing said ply such that said first side obtains a final surface roughness arithmetical mean height (Sa1), and said second side obtains a final surface roughness arithmetical mean height (Sa2), wherein a difference between the final surface roughness arithmetical mean heights of the first side and the second side is 7 μm or less (|Sa1−Sa2|≤7 μm) and said ply obtains a final bulk of at least 7.5 cm.sup.3/g, and said step of processing said ply comprises a step of micro-embossing said ply, and a step of calendering said ply subsequent to said step of micro-embossing said ply.

15. Method according to claim 14, wherein said step (S21) of micro-embossing said ply comprises micro-embossing with from 30 to 80 dots/cm.sup.2.

16. Method according to claim 14, wherein said step (S21) of micro-embossing said ply is performed by Accurate Bulk Embossing (ABE).

17. Method according to claim 14, wherein said step (S21) of micro-embossing said ply is performed by Matched Steel embossing.

18. (canceled)

19. Method according to claim 14, wherein said step of micro-embossing said ply is performed such that that said first side obtains an intermediary surface roughness arithmetical mean height (inSa1), and said second side obtains an intermediary surface roughness arithmetical mean height (inSa2), and said step of calendering said ply is performed such that that said first side obtains said final surface roughness arithmetical mean height (Sa1), and said second side obtains said final surface roughness arithmetical mean height (Sa2), wherein a difference between the intermediary surface roughness arithmetical mean heights (|inSa1−inSa2|) is less than or equal to said difference between the final surface roughness arithmetical mean heights (|Sa1−Sa2|).

20. Method according to claim 14, wherein said step of micro-embossing said ply is performed such that said first side obtains an intermediary developed interfacial area ratio (inSdr1) and said second side obtains an intermediary developed interfacial area ratio (inSdr2), and said subsequent step of calendering said ply is performed such that said first side obtains a final developed interfacial area ratio (Sdr1) and said second side obtains a final developed interfacial area ratio (Sdr2), and wherein a difference between said intermediary developed interfacial area ratios (|inSdr1−inSdr2)| is less than or equal to a difference between said final developed interfacial area ratios (|Sdr1−Sdr2)|).

21. Method according to claim 14, wherein said step of processing said ply comprises processing said ply such that said first side obtains a final developed interfacial area ratio (Sdr1) and said second side obtains a final developed interfacial area ratio (Sdr2), and a difference between the final developed interfacial area ratios of the first side and the second side is 2% or less (|Sdr1−Sdr2|≤2%).

22. Method according to claim 14 wherein said step of providing a ply comprises providing a ply which is a structured tissue ply, preferably which is produced by TAD technology or alternatively a ply which is produced by ATMOS technology.

23. Method according to claim 14, comprising a step of converting said ply to a product consisting of said ply.

24. Method according to claim 14 comprising producing an absorbent tissue paper product comprising one ply being an essentially continuous ply of a fibrous structure having a first side and a second side, said first side having a surface roughness arithmetical mean height (Sa1), and said second side having a surface roughness arithmetical mean height (Sa2), said ply-being a structured tissue paper ply, wherein said ply has a micro-embossed structure and a difference between the surface roughness arithmetical mean heights of the first side and the second side is 7 μm or less (|Sa1−Sa2|≤7 μm), and in that said ply has a bulk of at least 7.5 cm.sup.3/g.

25. Apparatus for performing the method according to claim 14, said apparatus comprising an embossing station and a calendering station.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] Below follows a more detailed description of an example product, method and apparatus with reference to the appended drawings, wherein:

[0073] FIG. 1 is schematic view of a variant of a product as disclosed herein;

[0074] FIG. 2 is a flow chart of a variant of a method as disclosed herein;

[0075] FIG. 3 is a schematic view of a variant of an apparatus as disclosed herein.

DETAILED DESCRIPTION

[0076] Throughout this application, the parameters used are defined as follows:

[0077] Sa:

[0078] Sa is the extension of Ra (arithmetical mean height of a line) to a surface. It expresses, as an absolute value, the difference in height of each point compared to the arithmetical mean of the surface. This parameter is used generally to evaluate surface roughness.

[0079] Sdr:

[0080] Sdr (Developed interfacial area ratio)

[0081] The Sdr parameter is the ratio between the area of the “real” developed surface and the area of the “projected” surface.

[0082] The Sdr of a completely planar surface is 0.

[0083] Sa and Sdr are defined by ISO25178 using a non-contact type method.

[0084] Basis weight: Basis weight is determined in accordance with ISO 12625-6:2016.

[0085] Thickness: Thickness is determined in accordance with ISO 12625-3.

[0086] Bulk: Bulk is determined by the ratio thickness/basis weight.

[0087] CD wet strength: CD wet strength is measured in accordance with ISO 12625-5.

[0088] Absorption capacity: Absorption capacity was measured according to ISO12625-8:2011.

[0089] Panel Softness:

[0090] Panel softness is determined by evaluation made by panel members. The panelists rank products in terms of softness (handfeel). The Softness Panel values are therefore comparative values enabling a comparison between the samples tested, rather than an absolute parameter. The softer the product/tissue base sheet is rated the higher the value will be.

[0091] Each sample is composed of one product, i.e. a multi-ply tissue paper product. The dimensions of the samples are therefore the dimensions of the finished products. Samples are conditioned for minimum 2 hours in a controlled area at 23° C. and 50% relative humidity.

[0092] The different samples are comfort rated by ten panelists, and an average comfort rating for each product is determined over the panelists. Samples are placed in MD in front of the panelists. Hence, softness panel values are comparative values within a test and indicate the perceived softness of a product.

[0093] For the purpose of this application, softness panel values given in one and the same table are comparable and indicate the perceived relative softness of the products tested. The higher the value of the rating, the more comfortable is the product.

[0094] With the absorbent tissue paper products of the present disclosure, an absorbent paper tissue product is proposed which may preferably consist of one single ply, and yet allow both sides of the product to display the same soft and pleasant surface to a user.

[0095] FIG. 1 illustrate schematically a variant of an absorbent tissue paper product, which absorbent tissue paper product consists of one single ply 10, said ply being an essentially continuous ply of fibrous structure. The ply 10 has a first side 1 and a second side 2, said first side 1 having a surface roughness arithmetical mean height Sa1, and said second side 2 having a surface roughness arithmetical mean height Sa2.

[0096] Further, a difference between the surface roughness arithmetical mean heights of the first side 1 and the second side 2 is 7 μm or less (|Sa1−Sa2|≤7 μm) and the bulk of said ply is from 7.5 cm.sup.3/g.

[0097] Optionally, the absorbent paper tissue product presents any of the features as set out in the summary section of the application, alone or in combination.

[0098] For example, advantageously said first side 1 of the ply 10 may have a developed interfacial area ratio (Sdr1) and said second side 2 of the ply 10 may have a developed interfacial area ratio (Sdr2), and a difference between the developed interfacial area ratios of the first side and the second side is 2% or less (|Sdr1−Sdr2|≤2%).

[0099] Moreover, the ply 10 may advantageously present a basis weight within the range of 18 to 60 gsm, a thickness within the range of 0.1 to 0.5 mm, a CD wet strength within the range of 40 to 120 N/m, and/or an absorption capacity of more than 7 g/g.

[0100] Optionally, and preferably, the ply (10) may have a micro-embossed structure with from 30 to 80 dots/cm.sup.2.

[0101] FIG. 2 illustrate schematically a method as proposed herein, which may be used to provide a product e.g. as exemplified in FIG. 1.

[0102] As such, the method is a method for producing an absorbent tissue paper product comprising the steps of [0103] S10: providing one essentially continuous ply of fibrous structure having a first side and a second side, and [0104] S20: Processing said ply such that said first side obtains a surface roughness arithmetical mean height Sa1, and said second side obtains a surface roughness arithmetical mean height Sa2, wherein a difference between the surface roughness arithmetical mean heights of the first side and the second side is 7 μm or less (|Sa1−Sa2|≤7 μm) and the bulk of said ply is at least 7.5 cm.sup.3/g.

[0105] According to an example variant, the ply which is initially provided and to be processed as set out in the above, is a structured tissue paper produced by a TAD paper machine. The TAD paper making process is well known and results in a structured paper tissue web having a relatively low density, but also two distinct different sides, a Hood side that is relatively rough, and a Yankee side that is relatively smooth and soft. Hence, TAD ply provided in the first step of the method has a relatively high two-sidedness, and would generally not fulfil the requirements as set out in the above for the desired tissue paper product, especially as regards softness to touch.

[0106] In another example variant, the base ply is instead a structured tissue paper produced by a ATMOS paper machine. Also this type of structure tissue paper generally has a relatively high two-sidedness.

[0107] In addition, said step S20 of processing said ply comprises a step S21 of micro-embossing said ply.

[0108] By micro-embossed is as set out in the above meant an embossing where the embossing rolls provides the ply with at least 30 embossing dots per cm.sup.2. For example, from 30 to 80 dots/cm.sup.2, or preferably from 40 to 60 dots/cm.sup.2 may be used.

[0109] Optionally, the micro-embossing may be performed by MS embossing or ABE embossing. By adjusting the gap between the rolls in these embossing techniques in relation to the thickness of the structured paper tissue ply, a surprisingly effective reduction of the two-sidedness between the first and the second side may be achieved. In other words, the embossing pattern and the embossing gap may be adjusted so as to reduce the difference between the surface roughness arithmetical mean heights of the first side and the second side, for the specific base ply in question.

[0110] In some cases, the micro-embossing alone is sufficient to process the base ply so as to arrive at the desired difference between the final surface roughness arithmetical mean heights of the two plies, and the desired bulk.

[0111] However, even if the ply after micro-embossing might display a satisfactory two-sidedness, it may still provide a rough hand-feel to a user.

[0112] Optionally, the method comprises a calendering step S22 performed after said micro-embossing step S21. The calendering step S22 may be used to achieve the final desired thickness of the ply and to improve the softness. The calendering may take place between two smooth metal rolls, or alternatively between one metal roll and one rubber roll.

[0113] The micro-embossing step will in general increase the thickness of the ply, and reduce the two-sidedness. The calendering step will in contrast decrease the thickness of the ply, and improve softness perception.

[0114] Purely as an example, a variant of the method as proposed herein for producing a variant of the product as proposed herein will be described in the following. Reference is made to Table 1 in the below.

TABLE-US-00001 TABLE 1 Basis weight Thickness Bulk |Sa1-Sa2| |Sdr1-Sdr2| Panel Absorption g/m.sup.2 mm/ply cm3/g μm % — g/m.sup.2 Base sheet 25.8 0.41 15.9 15.0 6.3 1.4 294 Calendered base sheet 25.0 0.36 14.4 0.6 1.3 1.6 277 Micro-emboss (ABE) 26.1 0.57 21.9 1.8 3.7 1.2 326 Micro-emboss (ABE + 25.4 0.39 15.4 5.9 2.3 2.4 302 calendering)

[0115] In the examples, the absorbent tissue paper products produced and evaluated comprised one single ply only. The properties of the single plies set out in Table 1 are therefore also the properties of the corresponding absorbent tissue paper products.

[0116] In a first example, the starting point is a ply (the base sheet) being TAD ply having a thickness of 0.41 mm, and a difference between the surface roughness arithmetical mean heights of the first side and the second side being about 15 μm. When evaluated by a softness panel, the panel softness rating for the ply was 1.4, a value which in this case indicated a non-satisfactory softness for an absorbent tissue product.(see line 1 in Table 1)

[0117] In a second example, the same base sheet is calendered. This results in the difference between the surface roughness arithmetical mean heights of the first side and the second side going down to only 0.6 μm. However, the panel softness rating of the calendred base sheet increases only slightly as compared to the uncalendered base sheet, to 1.6 (see line 2 in Table 1).

[0118] In a third example, the same initial base sheet is micro-embossed by ABE. This results in the difference between the surface roughness arithmetical mean heights of the first side and the second side becoming 1.8 μm. The panel softness rating of the micro-embossed base sheet decreases slightly when compared to the base sheet, to a rating of 1.2 (see line 3 in Table 1)

[0119] In a fourth example, the same initial base sheet is first micro-embossed (as in line 3 of Table 1), then calendared. The difference between the surface roughness arithmetical mean heights of the first side and the second side increases when compared to the ply being only micro-embossed, said difference being 5.9 μm. Still, the difference is within the range of 7 μm or less as proposed in this application, indicating a satisfactory low two-sidedness. Notably, the panel softness rating of the micro-embossed and calendared base sheet increases to 2.4, which in this case indicates that a satisfactory softness for an absorbent tissue product is achieved (see line 4 in Table 1).

[0120] In view of the above examples, it is seen how a reduction of the two-sidedness of the ply by means of micro-embossing enables achieving products having advantageous properties especially when it comes to softness. In particular, it enables production of an absorbent tissue paper product comprising one ply, which ply is micro-embossed and calendered, and which ply displays a low two-sidedness as proposed herein. Since such a ply may (as demonstrated by the above examples) display advantageous softness to touch in combination with said low two-sidedness, meaning that such a ply is particularly suitable for forming an absorbent tissue paper product consisting of such a ply only.

[0121] In view of the above example, it is understood that a person skilled in the art may elaborate using the micro-embossing step and the calendering step so as to achieve a product as proposed herein and with various other features as desired.

[0122] For example, optionally said step S21 of micro-embossing said ply is performed such that that said first side obtains an intermediary surface roughness arithmetical mean height inSa1, and said second side obtains an intermediary surface roughness arithmetical mean height inSa2, and said step S22 of calendering said ply is performed such that that said first side obtains said final surface roughness arithmetical mean height Sa1, and said second side obtains said final surface roughness arithmetical mean height Sa2, wherein a difference between the intermediary surface roughness arithmetical mean heights (|inSa1−inSa2|) is less than or equal to in said difference between the final surface roughness arithmetical mean heights (|Sa1−Sa2|). In other words, although the calendaring step may increase the two-sidedness, as compared to a ply being micro-embossed only, the person skilled in the art may adapt the production method so as to still achieve a final product falling within the ranges proposed herein.

[0123] The reasoning in the above regarding difference between the surface roughness arithmetical mean height values of the first and second side of the ply is similarly applicable to the intermediary and final difference between the developed interfacial area ratios of the first and second ply, which final difference is preferably 2% or less (|Sdr1−Sdr2|≤2%).

[0124] The step S20 of processing said ply may further comprise processing the ply so as to obtain any of the features of the product as set out in the summary section of the application.

[0125] Further, the method may comprise a step S30 of converting said ply 10 to a product, preferably a step of forming said ply to a product consisting of said ply 10. This step may involve e.g. cutting, perforating, folding or rolling said ply 10.

[0126] FIG. 3 schematically illustrates an apparatus for performing a method as disclosed herein/producing a product as disclosed herein, said apparatus 100 comprising an embossing station 110 and a calendering station 120.

[0127] The embossing station 110 and/or the calendering station 120 may optionally be adapted to perform any of the steps of the method as described in this application.

[0128] Optionally, the apparatus may comprise a forming station 130 for forming said ply into final products. To this end, the forming station 130 may comprise one or more stations such as cutting, perforating folding or rolling stations.

[0129] Numerous variants and options of the product, method and apparatus as disclosed herein will be conceivable by the person skilled in the art.

[0130] For example, the product may comprise embossings in addition to the micro-embossing, such embossings may be made together with colour print.