• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    This invention relates to the use of fibrillated lyocell fibers for making a nonwoven web material, particularly for use with a wipe, by use of a foaming process.
    公开号:AT517303A1
    申请号:T368/2015
    申请日:2015-06-11
    公开日:2016-12-15
    发明作者:
    申请人:Chemiefaser Lenzing Ag；
    IPC主号:
    专利说明:

    Use of cellulosic fibers for producing a nonwoven fabric
    This invention relates to the use of fibrillated lyocell fibers for making a nonwoven material, particularly for use with a wipe, by the use of a foaming process. For the purposes of the present invention, such nonwoven materials are also referred to as papers and vice versa, and terms such as "paper machine", "papermaking" etc. should be construed accordingly.
    State of the art
    In the paper industry, the foam process, where foam serves as the carrier phase of materials, is used in both web forming and web coating processes. The process is described, for example, in the following publications: Radvan B., Gatward A.P.J., The formation of wet-laid webs by a foaming process, Tappi, Vol. 55 (1972), p. 748; in a report by Wiggins Teape Research and Development Ltd, New process uses foam in papermaking instead of avoiding it, Paper Trade Journal, Nov. 29, 1971; and in Smith Μ. K., Punton V.W., Rixson A.G., The structure and properties of a foaming process, TAPPI, Jan. 1974, Vol. 57, No. 1, pp. 107-111.
    In GB 1 395 757 an apparatus for producing a foamed fiber dispersion for use in the manufacture of paper is described. A surfactant is added to the fiber pulp having a fiber length greater than about 3 mm to provide a dispersion having an air content of at least 65% to be dispensed onto the dewatering wire of a paper machine. The aim is to achieve a homogeneous formation of the fiber web on the wire.
    As early as the mid-1970s, the foam molding process was successfully implemented on a production machine. In the Wiggins-Teape-Radfoam process (Arjo Wiggins), fibers were suspended from the screen belt (a screen belt is also referred to herein as "wire" - a term used by experts in the field) of a conventional four-wire paper machine in aqueous foam fed. The development team obtained a non-layered 3D structure of papers made on a four-wire paper machine with very high fiber concentrations (3-5%) in water by the foam process.
    A comparison of the foam and water-forming processes appears to indicate a trend from the prior art: in foam molding, the volume is greater but the tensile index is smaller, which may be a disadvantage in many applications for such materials. For a bulkier structure, the structure is more porous, resulting in lower tensile index values. An interesting result from a comparison of water and foam test specimens was that tensile stiffness indices were very close to each other in both cases, although foam-formed specimens were far bulkier. The reason for this is currently unknown and requires further research.
    As currently understood, the major problems that prevented foam molding from becoming a standard web forming technique in papermaking and board making were: too much porosity in some applications, reduced strength properties compared to normal low consistency wet-forming, poor tensile strength, and poor modulus of elasticity.
    With foam method, a higher volume (lower density) can be achieved compared to normal wet-laying method. For conventional printing and packaging paper, paperboard and board grades, the major drawbacks are the loss of modulus of elasticity ("softness") and internal strength. However, the same properties are advantages in tissue manufacturing. Thus, foam molding is useful in tissue paper products, e.g. with wipes, far more usual.
    A recent approach to improved papermaking which aims to improve the dewatering and retention of papermaking chemicals in a fibrous web formed on a forming fabric is the incorporation of microfibrillated cellulose (MFC) into the pulp suspension. US 6,602,994 B1 teaches the use of derivatized MFC with electrostatic or steric functionality for the targets, which even include better web formation. According to this document, the microfibrils have a diameter in the range of 5 to 100 nm. However, the disadvantages associated with MFC are compression and high paper shrinkage, as well as a tendency for MFC to absorb and retain a substantial amount of water, increasing the amount of energy required to dry and reducing paper machine speed and productivity. For these reasons, the widespread use of MFC in the paper industry has not yet prevailed. In addition, the production of derivatized MFCs is costly because of the additional chemical derivatization step, and the functional groups on the cellulose chain can adversely alter the properties of the final product. WO 2013/160553 discloses an approach to overcoming the above-mentioned problems in printing and packaging papers, paperboards and cartons by providing a method of producing a foam-formed fibrous web which imparts significantly higher strength to paper, paperboard and paperboard products maintains, overcomes or significantly reduces low density. The solution according to WO 2013/160553 is the preparation of a web by the steps of (i) providing a foam of water and a surfactant, (ii) incorporating microfibrillated cellulose together with a pulp of longer fiber length into the foam of (iii ) Feeding the foam to a forming fabric, (iv) dewatering the foam on the forming fabric to form a web, and (v) subjecting the web to final drying. In particular, WO 2013/160553 discloses that a high fiber length pulp, mechanical or chemical, can be advantageously used in foam molding in combination with microfibrillated cellulose. Although the use of MFC in papermaking is known per se, incorporation of MFC into a foam is not considered to be proposed in the prior art, and the benefits were unpredictable to those skilled in the art. However, the web forming method of WO 2013/160553 requires the energy consuming step of pretreating the cellulose to induce microfibrillation, and the resulting web still lacks sufficient strength for many applications such as household wipes, personal care, hygiene, etc ., is required.
    task
    In view of this prior art, the object to be achieved by this invention was to provide a nonwoven web material having sufficient strength, even in a remoistened state, that can be produced with fewer pretreatment steps of the raw materials.
    description
    An object of the present invention is to overcome or substantially reduce the above-mentioned paper-related problems, especially in wiper applications, by providing a process for producing a foam-formed fibrous web which imparts increased strength to the paper products and particularly wipes while maintaining the low density ,
    The solution according to the invention is the production of a fibrous web of paper which comprises the steps of (i) providing a foam of water and a surfactant, (ii) incorporating lyocell fibers together with a pulp having a greater fiber length into the foam, iii) supplying the foam to a forming fabric, (iv) dewatering the foam on the forming fabric to form a web, and (v) subjecting the web to final drying. Surprisingly, it has been found that the use of lyocell fibers results in increased strength fibrous web materials, as set forth below.
    Preferably, the lyocell fibers are lyocell fibers having a denier between 0.5 and 30 dtex, preferably between 0.9 and 15 dtex, and a fibrillation coefficient Q between 10 and 50. The fibrillation coefficient Q is defined as: Q = 200 / tcsF200
    Where tCsF2oo is the time (in minutes) required to obtain a CSF value of 200 in the CSF test. The CSF test is performed with a staple length of 5 mm and then tested according to the Canadian Standard Freeness TAPPI Standard T227 om-94. The larger Q is, the shorter the time required to obtain the same degree of fibrillation under the same fibrillation conditions. Depending on the type of fibrous starting material, a Q value of up to 50 can be achieved.
    In a preferred embodiment, the lyocell fibers are lyocell fibers having increased tendency to fibrillate (also referred to herein as CLY-HF, i.e., "lyocell-high fibrillating"). Such lyocell fibers have a fibrillation coefficient Q between 20 and 50.
    By definition, the pulp to be combined with lyocell fibers has a relatively large fiber length, preferably about 1 mm or more. Preferred is a pulp having a weight-weighted average fiber length between 1.5 and 4 mm. This weighted average length means that the pulp may also contain a certain percentage of shorter or longer fibers. Particularly preferred is a pulp having a maximum length of the longest fibers of 6 mm.
    In particular, it has surprisingly been found that pulp having a high fiber length can be advantageously used in foam molding in combination with lyocell fibers.
    In a particularly preferred embodiment of the present invention, the ratio of the average length of the lyocell fibers to the average length of the pulp fibers is between 1: 1 and 10: 1 (length of lyocell fibers: length of pulp fibers).
    A method known in the art for making the CLY-HF is disclosed in US 6,042,769. US 6,042,769 discloses a method by which the
    Fibrillation tendency of lyocell fibers is increased by a treatment which reduces the degree of polymerization of the cellulose by at least 200 units. The fiber thus obtained should be used especially in nonwovens and paper applications. Preferably, the treatment is carried out with a bleaching agent, in particular with sodium hypochlorite. Alternatively, a treatment with acid, preferably with a mineral acid such as hydrochloric acid, sulfuric acid or nitric acid, is possible. This method has not yet been implemented on an industrial scale.
    It was also possible to prepare the required CLY-HF by subjecting conventional lyocell fibers to acid treatment. This acid treatment may be carried out by impregnating fiber tow extruded in a known manner according to the Lyocell method from spinnerets and having a single fiber titer between 1.0 and 6.0 dtex with dilute mineral acid, for example hydrochloric, sulfuric or nitric acid, at a concentration between 0.5 and 5% at room temperature in a vessel at a liquor ratio of for example 1:10 and then by pressing it to a certain residual moisture, for example 200%. Subsequently, the impregnated fiber cable is subjected to steam in a suitable device with overpressure and then washed free of acid and dried. Long fiber pulps particularly useful in the invention include chemical pulps, chemimechanical pulp (CMP), thermomechanical pulp (TMP), chemithermomechanical pulp (CTMP), GW and other high yield pulps such as APMP and NSSC.
    Without being bound by theory, it is believed that in combination, the long pulp fibers create the bulky structure and the lyocell fibers provide the connection between the long fibers. It was found that the inventive method, a volume between 2.5 cm3 / g and 15 cm3 / g, preferably between 8.0 cm3 / g and 11 cm3 / g, achieved.
    In foam molding, Lyocell is able to form bridges between individual long fibers and thus gives the web surprisingly good strength properties.
    Since foam molding prevents the formation of flocculation between long fibers, a very homogeneous surface mass can be achieved. This improves the uniformity of print quality because there are fewer variations in thickness in the paper.
    These stiff long fibers are able to maintain the bulky structure in wet pressing and drying, and thus give the nonwoven fabric or paper product surprisingly good bulk.
    An interesting result compared to water and foam test specimens was that the tensile stiffness indices were very close to each other in both cases, although the foam-formed specimens were much bulkier. The reason for this is currently unknown and requires further research.
    According to one embodiment of the invention, an endless nonwoven web is formed on a large scale on a moving forming fabric of a paper machine, dewatered by suction through the web and the forming fabric, and finally dried in a drying section of the paper machine. In place of dewatering on the current forming fabric of a paper machine, which is usually a flat endless belt, dewatering may also be performed, for example, on a three-dimensional, water-permeable mold which allows the fibers to be retained but the water to be removed. In this embodiment of the invention, the drying is done by hot air, microwave drying or other suitable drying methods generally known to those skilled in the art. This embodiment of the invention makes it possible to produce three-dimensional bodies which are suitable, for example, as packaging or insulating materials.
    Another embodiment of the invention comprises dewatering the web by drawing air through the web and the forming wire at a pressure of at most 0.6 bar, followed by pre-drying by drawing air at a pressure of at most about 0.3 bar.
    According to a further embodiment of the invention, the fibrous components incorporated in the foam consist of about 5 to 40 wt .-%, preferably from 10 to 40 wt .-% and in particular from 10 to 25 wt .-% Lyocell fibers and from about 60 to 95 wt .-%, preferably from 60 to 90 wt .-% and in particular from 75 to 90 wt .-% pulp with longer fibers. "Longer fibers" means a weight-weighted average fiber length between 1.5 and 4 mm. Particularly preferred is a pulp having a maximum length of the longest fibers of 6 mm.
    According to yet another embodiment of the invention, the foam is brought to an air content of 60 to 70 vol .-% before it is fed to the forming fabric. The consistency of the pulp subjected to foaming may be 1 to 2% based on the amount of water. A suitable amount of surfactant in the foam may range from 0.05 to 2.5 weight percent, but will be readily determined by one skilled in the art.
    The preferred surfactant for use in the invention is sodium dodecyl sulfate (SDS), although other conventional surfactants can be used. Foam forming by using long cellulosic fibers and added lyocell fibers in the foam is thus a very suitable and promising method of producing all paper grades which require the best possible web formation in combination with the best possible flexural stiffness.
    The fibrous web of the present invention, which can be made by the process described above, comprises a mixture of lyocell fibers and a pulp of greater fiber length, as set forth above, and has a density between 2.5 cc / g and 15 cc / g. preferably between 8.0 cm3 / g and 11 cm3 / g. The density is calculated as ((basis weight) x (thickness)) '1. In a preferred embodiment, the lyocell fibers are Lyocell fibers with increased fibrillation tendency (CLY-HF).
    Generally, the fibrous web comprises about 5-40 wt% lyocell fibers and about 60-95 wt% longer fiber pulp. The fibrous web preferably comprises 10 to 40% by weight and in particular 10 to 25% by weight lyocell fibers and also about 60 to 95% by weight, preferably 60 to 90% by weight and in particular 75 to 90% by weight. Pulp with longer fibers. "Longer fibers" means a weight-weighted average fiber length between 1.5 and 4 mm. Particularly preferred is a pulp having a maximum length of the longest fibers of 6 mm.
    Such products include, for example, all types of paper suitable for nonwoven products, including, but not limited to, wipes, especially wet wipes, baby wipes, cosmetic wipes, face masks, other body wipes, wipes for technical and cleaning purposes, toilet paper, etc.
    The high-volume high-strength structure obtained according to the invention can also be used, for example: as a middle layer in multilayer structures (papers, boards and cardboards) when laminating to other paper structures and / or plastic film layers, as a fibrous base for extrusion coating with plastics, as thermal insulation, sound insulation, liquid and moisture absorbent material, as a moldable layer in shaped structures such as trays, cups, containers.
    Since the fibrous web of the invention can be used as a single ply in a multi-ply board or a multi-ply paperboard, it is preferably arranged as a middle ply, while the outer ply plies can be fibrous webs having a smaller volume than the middle ply. However, it is possible to produce all the layers of a multi-ply board or a multi-ply board by means of the foam molding process according to the invention.
    A further aspect of the present invention is the use of the fibrous web described in this document for the production of a wipe, wherein the fibrous web is used as at least one layer of the wipe. For example, the fibrous web may be used as the middle layer of the wipe, while the wipe further includes outer layers having a smaller volume than that of the middle layer.
    Possible uses of the fibrous web of the present invention may include, but are not limited to, wet disposable wipes, flushable wipes, dry wipes, paper towels, face masks (also flushable face masks), napkins, disposable tablecloths, absorbent core products, sealing materials, and the like.
    The invention will now be illustrated by way of examples. These examples in no way limit the scope of the invention. The invention also includes any other embodiments based on the same inventive idea.
    Examples
    Example 1: Preparation of CLY-HF
    Fast fibrillating lyocell fibers of the present invention are prepared as follows: Lyocell fiber tow having a single fiber titer of 1.7 dtex is impregnated with dilute sulfuric acid at room temperature and a liquor ratio of 1:10 and pressed to about 200% moisture. The impregnated fiber tow is steamed under pressure in a laboratory steam for about 10 minutes, then acid washed with water and dried. The dry fiber cable is cut to a staple length of 6 mm.
    Example 2: Forming a nonwoven web
    The webs were made according to the following general procedure:
    Raw materials used:
    Pulp: a commercial spruce long fiber kraft pulp having a weighted average fiber length of 2.6 mm.
    Man-made fibers (the content of these fibers is hereinafter referred to as "fiber content" while the remainder is pulp) - see Table 1. a. Lyocell short cut fiber, manufactured by Lenzing Aktiengesellschaft, Austria, cut to 6 mm staple length according to a conventional Lyocell method; Titer: 1.7 dtex; commercially available as Tencel® Shortcut. b. Viscose fiber of rectangular cross section; Staple length: 10 mm; Titer: 2.4 dtex, commercially available ["viscose"]. c. The fiber prepared according to Example 1; Staple length: 6 mm; Titer: 1.7 dtex ["CLY-HF"].
    Table 1:
    Foam-laid handsheets the size of a sheet of A4 size paper were prepared by the following procedure: Foam was prepared by mixing water with sodium dodecylsulfate (SDS) as a surfactant in a ratio of 0.15-0.2 g / l with a stirrer (3500 rpm) until the air content of foam was 60-70%. The desired air content of foam was determined by the foaming arrangement: as the foam reaches the setpoint air level, the level of the foam surface no longer increases and the mixing process begins to reduce the bubble size of the foam. Once the foam was finished, a fiber suspension comprising CLY-HF (prepared according to Example 1) and the pulp in the proportions shown in Table 1 were mixed with the prepared foam. The mixing was continued until the target air content was reached again. In a stable state, the distances between fiber particles in the foam remained constant and flocculation did not occur. Thereafter, the foam was decanted into a hand pattern mold and filtered through a wire by means of a nipple and a vacuum chamber. The wire was of the type conventionally used for water-based forming. Then, the wire and the hand pattern formed thereon were removed from the mold and pre-dried on a suction table by using a nipple. The suction table has a 5 mm wide suction slot, which sucks air through the hand pattern with 0.2 bar vacuum.
    The webs were dried according to the following procedure:
    The wet handsheets in A4 format were dried on a special tumble dryer: This dryer rotates (1 cycle within 3 minutes) to dry the sample to a completely dry state. To convey the sheet over the rotating drum, a fabric carries the sample on the heated drum. Since a certain area at the bottom of the dryer is open, the sheet falls down into a collection section as it goes through the entire process. After drying, the absolutely dry leaves are reconditioned overnight in a reconditioning room.
    The tensile strength values given below were measured according to DIN 29073, Part 3, (identical to ISO 9073-3) in the machine direction (MD) and transverse direction (CD). The values measured here are the maximum tensile strengths in the unit Newton and the elongation in%.
    The results of Example 2 (see Fig. 1, Fig. 2) show that the papers produced according to the invention exhibit equal or even higher toughness (ie strength) in both directions as well as pulp-only papers even in the original dried state , while the blends with other chemical cellulose fibers always have reduced toughness as compared to pulp-only paper made according to the same process.
    Example 3: Rewetting dried nonwoven webs:
    The tensile strength values shown in FIG. 3 and FIG. 4 were measured according to DIN 29073, part 3, (identical to ISO 9073-3) in the machine direction (MD) and transverse direction (CD). In this example, the samples were remoistened to 150 weight percent water to 2.5 times their dry weight.
    The rewet condition is the commercially relevant condition as wet wipes are usually made by the processor (the reel manufacturer produces the web, the processor processes the web to the required size by adding lotion and cutting the wipe).
    According to Example 3, the papers produced according to the invention have increased wet strength compared to the product of 100% pulp in the rewet state (see Fig. 3, Fig. 4). Even when comparing the papers produced according to the invention with the other fibers, CLY-HF turns out to be advantageous again. This effect is clearly visible both in the machine direction and in the transverse direction.
    Conclusion:
    For all test specimens, the strength of the sheets produced according to the invention is considerably higher, compared with the rewet condition. It can be seen that as the fiber content in the sheets is increased, the tensile strength decreases. Lyocell fibers do not have this effect. In the machine direction, the tensile strength is comparable, in the transverse direction, there is an increase in tensile strength.
    权利要求:
    Claims (15)
    [1]
    claims
    A method of making a fibrous web of paper comprising the steps of: a. Providing a foam of water and a surfactant, b. Incorporation of lyocell fibers together with a pulp of longer fiber length into the foam, c. Feeding the foam onto a forming fabric, d. Dewatering the foam on the forming wire to form a sheet, and e. Subjecting the web to a final drying.
    [2]
    2. The method according to claim 1, characterized in that the lyocell fibers are lyocell fibers having a titer between 0.5 and 30 dtex, preferably between 0.9 and 15 dtex, and a fibrillation coefficient Q between 10 and 50.
    [3]
    3. The method according to claim 1, characterized in that the lyocell fibers are lyocell fibers having an increased fibrillation tendency.
    [4]
    4. The method according to claim 1, characterized in that a Endlosrbahn formed on a running Formiersieb a paper machine formed by suction through the web and the forming fabric and finally dried in a drying section of the paper machine.
    [5]
    A method according to claim 1, characterized in that the web is dewatered by sucking air through the web and the forming wire at a pressure of at most 0.6 bar, followed by pre-drying by sucking air at a pressure of at most about 0, 3 bar.
    [6]
    6. The method according to any one of the preceding claims, characterized in that the fiber components incorporated in the foam from about 5 to 40 wt .-%, preferably from 10 to 40 wt .-% and in particular from 10 to 25 wt .-% lyocell Consist of about 60 to 95 wt .-%, preferably from 60 to 90 wt .-% and in particular from 75 to 90 wt .-% pulp with longer fibers.
    [7]
    A method according to any one of the preceding claims, characterized in that the foam is brought to an air content of 60 to 70% by volume before being fed to the forming fabric.
    [8]
    Fiber web which can be made by the method according to any one of the preceding claims, characterized in that the web comprises a mixture of lyocell fibers and a pulp with a greater fiber length and that the web has a volume of at least 2.5 cm 3 / g, preferably between 8.0 cm3 / g and 11 cm3 / g.
    [9]
    The fibrous web according to claim 8, characterized in that the lyocell fibers are lyocell fibers having a denier between 0.5 and 30 dtex, preferably between 0.9 and 15 dtex, and a fibrillation coefficient Q between 10 and 50.
    [10]
    10. fiber web according to claim 8, characterized in that the lyocell fibers are lyocell fibers with increased fibrillation tendency.
    [11]
    The fibrous web according to claim 8, characterized in that the web has a volume of between 2.5 cm 3 / g and 15.0 cm 3 / g and particularly preferably a volume of between 8.0 cm 3 / g and 11.0 cm 3 / g.
    [12]
    12. fiber web according to claim 8, characterized in that the web about 5 to 40 wt .-%, preferably 10 to 40 wt .-% and in particular 10 to 25 wt .-% lyocell fibers and about 60 to 95 parts by weight. %, preferably 60 to 90 wt .-% and in particular 75 to 90 wt .-% pulp with a greater fiber length comprises.
    [13]
    13. Use of the fibrous web according to any one of claims 8 - 12 for the production of a wipe, characterized in that the fibrous web is used as at least one layer of the wipe.
    [14]
    14. Use according to claim 13, characterized in that the fibrous web is used as a middle layer of the wipe and that the wipe further comprises outer layers having a volume smaller than that of the middle layer.
    [15]
    Use of the fibrous web according to any one of claims 8-12 for the production of wet disposable wipes, rinsable wipes, dry wipes, paper towels, face masks (including flushable face masks), napkins, disposable towels, absorbent core products, sealing materials, wet wipes, baby wipes, Cosmetic wipes, other body wipes, wipes for technical and cleaning purposes and toilet paper.
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    ATA368/2015A|AT517303B1|2015-06-11|2015-06-11|Use of cellulosic fibers for producing a nonwoven fabric|ATA368/2015A| AT517303B1|2015-06-11|2015-06-11|Use of cellulosic fibers for producing a nonwoven fabric|
    ES16713279T| ES2770000T3|2015-06-11|2016-02-29|Use of cellulosic fibers for the manufacture of a non-woven fabric|
    PCT/AT2016/000022| WO2016197156A1|2015-06-11|2016-02-29|Use of cellulosic fibers for the manufacture of a nonwoven fabric|
    KR1020187000393A| KR20180018656A|2015-06-11|2016-02-29|Uses of Cellulose Fibers for Making Nonwoven Fabrics|
    JP2017563595A| JP7028400B2|2015-06-11|2016-02-29|Use of cellulosic fibers to manufacture non-woven fabrics|
    EP16713279.4A| EP3307951B1|2015-06-11|2016-02-29|Use of cellulosic fibers for the manufacture of a nonwoven fabric|
    CN201680033277.1A| CN107683358A|2015-06-11|2016-02-29|Cellulose fibre is used for the purposes for manufacturing non-woven cloth|
    US15/580,936| US10604897B2|2015-06-11|2016-02-29|Use of cellulosic fibers for the manufacture of a nonwoven fabric|
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