US 12,116,732 B2
Paper products incorporating surface enhanced pulp fibers and having decoupled wet and dry strengths and methods of making the same
Bradley Langford, Fort Mill, SC (US); David Lloyd, Fort Mill, SC (US); Brian Ranson, Fort Mill, SC (US); Gwen Johnston, Fort Mill, SC (US); and Dale Kavalew, Fort Mill, SC (US)
Assigned to Domtar Paper Company, LLC, Fort Mill, SC (US)
Appl. No. 17/754,082
Filed by Domtar Paper Company, LLC, Fort Mill, SC (US)
PCT Filed Sep. 23, 2020, PCT No. PCT/US2020/052179
§ 371(c)(1), (2) Date Mar. 23, 2022,
PCT Pub. No. WO2021/061747, PCT Pub. Date Apr. 1, 2021.
Claims priority of provisional application 62/904,413, filed on Sep. 23, 2019.
Prior Publication US 2022/0333314 A1, Oct. 20, 2022
Int. Cl. D21H 27/40 (2006.01); B31F 1/07 (2006.01); D21D 1/34 (2006.01); D21H 11/02 (2006.01); D21H 17/26 (2006.01); D21H 17/55 (2006.01); D21H 21/20 (2006.01); D21H 27/02 (2006.01)
CPC D21H 27/40 (2013.01) [D21D 1/34 (2013.01); D21H 11/02 (2013.01); D21H 17/26 (2013.01); D21H 17/55 (2013.01); D21H 21/20 (2013.01); D21H 27/02 (2013.01); B31F 1/07 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A method of making a paper product, the method comprising:
laminating and/or embossing one or more sheets such that a total dry tensile strength of the paper product is less than or equal to 90% of the sum of the total dry tensile strength(s) of the sheet(s);
wherein each of the sheet(s) comprises one or more furnishes each comprising:
a plurality of first fibers that are hardwood fibers; and
a plurality of second fibers including softwood fibers and surface enhanced pulp fibers (SEPF) having a length weighted average fiber length that is at least 0.20 millimeters (mm), wherein the SEPF are made by refining a pulp feed, the refining including for each of one or more mechanical refiners:
introducing the pulp feed between two refining elements of the refiner, each of the refining elements comprising:
a plurality of bars, each protruding from a surface of the refining element and having a width that is less than or equal to 1.3 mm; and
a plurality of grooves defined by the bars, each having a width that is less than or equal to 2.5 mm; and
rotating at least one of the refining elements;
wherein refining the pulp feed is performed such that the refiner(s) consume at least 300 kilowatt-hours (kWh) per ton of fiber in the pulp feed; and
introducing one or more wet strength resins to the one or more furnishes such that, per ton of fiber in the one or more furnishes, at least 13 kilograms (kg) of a first wet strength resin and/or at least 2.5 kg of a second wet strength resin are introduced,
wherein the paper product has a basis weight of greater than 51.6 gsm; and
wherein by weight:
at least 90% of the second fibers are the softwood fibers; and
between 1% and 10% of the second fibers are the SEPF.