Use of fractionated fiber furnishes in the manufacture of tissue products, and products produced thereby

Abstract

A product and process of making an absorbent paper article such as paper products, towels, napkins and the like is disclosed. A product having superior properties of softness, handfeel, and strength is disclosed. The product may show a reduced degree of sloughing, that is, a reduction in the amount of paper particles or flakes that are generated from the product upon the abrasion of the paper product. In one embodiment, a two furnish process is employed. In some applications, both hardwood fibers and softwood fiber sources may be employed. At least one fiber furnish is fractionated or separated into short and long fiber fractions. The resulting product exhibits reasonably good strength and softness, with reduced sloughing.

What is claimed is:  
     
         1 . A method of making a paper product having at least one ply, comprising: 
 (a) providing a first furnish of fibers;    (b) providing a second furnish of fibers;    (c) fractionating the first furnish into a long fiber fraction and a short fiber fraction;    (d) diverting the short fiber fraction to the second furnish to form a third furnish;    (e) forming a first and second exterior layer using the third furnish;    (f) forming a first interior layer using the long fiber fraction of the first furnish; and    (g) combining at least the first and second exterior layers with the first interior layer to form a first ply.    
     
     
         2 . The method of  claim 1  comprising the additional steps of: forming a second interior layer using the long fiber fraction of the first furnish, and 
 combining the second interior layer with the first and second exterior layers and the first interior layer to form a first ply.  
 
     
     
         3 . The method of  claim 1  in which the first furnish comprises softwood fibers.  
     
     
         4 . The method of  claim 3  in which the second furnish comprises hardwood fibers.  
     
     
         5 . The method of  claim 1  in which the third furnish comprises hardwood fibers.  
     
     
         6 . The method of  claim 1  comprising the additional steps of: 
 (h) repeating steps (e)-(g) to form a second ply, and  
 (i) combining the first ply with the second ply to form a multi-ply paper product.  
 
     
     
         7 . The method of  claim 4  in which the hardwood fibers comprise eucalyptus fibers.  
     
     
         8 . The method of  claim 7  in which the percentage of eucalyptus fibers in the paper product is between about 50 and about 80 percent.  
     
     
         9 . The method of  claim 8  in which the percentage of eucalyptus fibers in the paper product is between about 60 and about 70 percent.  
     
     
         10 . The method of  claim 9  in which the percentage of eucalyptus fibers in the paper product is about 65 percent.  
     
     
         11 . The method of  claim 4  in which the ratio of hardwood fibers to softwood fibers is about 2:1.  
     
     
         12 . A paper product having at least one ply, the product being made by a process including the following steps: 
 (a) providing a first furnish of fibers;    (b) providing a second furnish of fibers;    (c) fractionating the first furnish into a long fiber fraction and a short fiber fraction;    (d) diverting the short fiber fraction to the second furnish to form a third furnish;    (e) forming a first and second exterior layer using the third furnish;    (f) forming a first interior layer using the long fiber fraction of the first furnish; and    (g) combining at least the first and second exterior layers with the first interior layer to form a first ply.    
     
     
         13 . The product of  claim 12 , in which the process further includes the additional steps of: 
 forming a second interior layer using the long fiber fraction of the first furnish, and    combining the second interior layer with the first and second exterior layers and the first interior layer to form a first ply.    
     
     
         14 . The product of  claim 12  in which the first furnish comprises softwood fibers.  
     
     
         15 . The product of  claim 12  in which the second furnish comprises hardwood fibers.  
     
     
         16 . The product of  claim 12  in which the slough value for the product is less than about 6 mg, while employing about 20 cycles of abrasion, at a speed of about 80 cycles per minute.  
     
     
         17 . The product of  claim 12  in which: 
 (a) the slough value for the paper product is less than about 6 mg, while employing about 20 cycles of abrasion, at a speed of about 80 cycles per minute, and  
 (b) the product exhibits a Handfeel rating of between about 7.74 and about 8.  
 
     
     
         18 . The product of  claim 12  in which the product exhibits: 
 (a) a Handfeel rating of between about 7.74 and 8, and  
 (b) a tensile strength of between about 540 and about 773 grams/3 inch width.  
 
     
     
         19 . The product of  claim 17  in which: 
 the paper product further exhibits a tensile strength of between about 540 and about 773 grams/3 inch width.  
 
     
     
         20 . The product of  claim 15  in which the hardwood fibers comprise eucalyptus fibers.  
     
     
         21 . The product of  claim 20  in which the percentage of eucalyptus fibers in the product is between about 50 and about 80 percent by weight.  
     
     
         22 . The product of  claim 21  in which the percentage of eucalyptus fibers in the product is between about 60 and about 70 percent by weight.