BACKGROUND

Many tissue products, such as facial tissue, bath tissue, paper towels, industrial wipers, and the like, are produced according to a wet laid process. Wet laid webs are made by depositing an aqueous suspension of pulp fibers onto a forming fabric and then removing water from the newly-formed web. Water is typically removed from the web by mechanically pressing water out of the web that is referred to as "wet-pressing." Although wet-pressing is an effective dewatering process, during the process the tissue web is compressed causing a marked reduction in the caliper of the web and in the bulk of the web.

For most applications, however, it is desirable to provide the final product with as much bulk as possible without compromising other product attributes. Thus, those skilled in the art have devised various processes and techniques in order to increase the bulk of wet laid webs. For example, creping is often used to disrupt paper bonds and increase the bulk of tissue webs. During a creping process, a tissue web is adhered to a heated cylinder and then creped from the cylinder using a creping blade.

Another process used to increase web bulk is known as "rush transfer." During a rush transfer process, a web is transferred from a first moving fabric to a second moving fabric in which the second fabric is moving at a slower speed than the first fabric. Rush transfer processes increase the bulk, caliper, and softness of the tissue web.

As an alternative to wet-pressing processes, through-drying processes have developed in which web compression is avoided as much as possible to preserve and enhance the bulk of the web. These processes provide for supporting the web on a coarse mesh fabric while heated air is passed through the web to remove moisture and dry the web.

Additional improvements in the art, however, are still needed. In particular, a need currently exists for an improved process that includes unique fibers in a tissue web for increasing the bulk and softness of the web without having to subject the web to a rush transfer process or to a creping process. SUMMARY

In general, the present disclosure is directed to further improvements in the art of tissue and papermaking. Through the processes and methods of the present disclosure, the properties of a tissue web, such as bulk, stretch, caliper, and/or absorbency can be improved. In particular, the present disclosure is directed to a process for forming a nonwoven web, particularly a tissue web containing pulp fibers, in a foam-forming process. For example, a foam suspension of fibers can be formed and spread onto a moving porous conveyor for producing an embryonic web.

In one aspect, for instance, the present disclosure is directed to a method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 1 % by weight crimped synthetic fibers and at least 1 % by weight binder fibers; forming a wet sheet from the aqueous-based foam ; and drying the wet sheet to obtain the foam-formed substrate.

In another aspect, a substrate includes an aqueous-based polymer foam including at least 1 % by weight crimped synthetic fiber and at least 1 % by weight binder fiber, wherein the substrate is free of superabsorbent material.

In yet another aspect, a method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 2% by weight crimped binder fibers; forming a wet sheet from the aqueous-based foam ; and drying the wet sheet to obtain the foam-formed substrate, wherein the foam-formed substrate is free of

superabsorbent material, and wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

Other features and aspects of the present disclosure are discussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and aspects of the present disclosure and the manner of attaining them will become more apparent, and the disclosure itself will be better understood by reference to the following description, appended claims and accompanying drawings, where:

Figure 1 is a schematic illustration of a foam-formed wet sheet being transferred from a forming wire onto a drying wire on a pilot line;

Figure 2A is a photographic illustration of a foam-formed wet fibrous sheet without crimped fiber;

Figure 2B is a photographic illustration of a foam-formed wet fibrous sheet with crimped fiber;

Figure 3A is a surface scanning electron microscope (SEM) photographic illustration pictures of Codes C at a magnification level of 15X;

Figure 3B is a surface SEM photographic illustration of Code C at a magnification level of 120X;

Figure 3C is a surface SEM photographic illustration of Code D at a magnification level of 15X;

Figure 3D is a surface SEM photographic illustration of Code D at a magnification level of 120X;

Figure 3E is a surface SEM photographic illustration of Code E at a magnification level of 15X;

Figure 3F is a surface SEM photographic illustration of Code E at a magnification level of 120X;

Figure 4A is a cross-sectional SEM photographic illustration of Code C at a magnification level of 15X;

Figure 4B is a cross-sectional SEM photographic illustration of Code C at a magnification level of 120X;

Figure 4C is a cross-sectional SEM photographic illustration of Code D at a magnification level of 15X;

Figure 4D is a cross-sectional SEM photographic illustration of Code D at a magnification level of 120X;

Figure 4E is a cross-sectional SEM photographic illustration of Code E at a magnification level of 15X; and

Figure 4F is a cross-sectional SEM photographic illustration of Code E at a magnification level of 120X.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present disclosure.

The drawings are representational and are not necessarily drawn to scale. Certain proportions thereof might be exaggerated, while others might be minimized.

DETAILED DESCRIPTION

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary aspects of the present disclosure only, and is not intended as limiting the broader aspects of the present disclosure.

In general, the present disclosure is directed to the formation of tissue or paper webs having good bulk and softness properties. Through the process of the present disclosure, tissue webs can be formed, for instance, having better stretch properties, improved absorbency characteristics, increased caliper, and/or increased softness. In one aspect, patterned webs can also be formed. In one aspect, for instance, a tissue web is made according to the present disclosure from a foamed suspension of fibers.

There are many advantages and benefits to a foam-forming process as described above. During a foam-forming process, water is replaced with foam as the carrier for the fibers that form the web. The foam, which represents a large quantity of air, is blended with papermaking fibers. Because less water is used to form the web, less energy is required to dry the web. For instance, drying the web in a foam-forming process can reduce energy requirements by greater than about 10%, or such as greater than about 20%, in relation to conventional wet pressing processes.

Foam-forming technology has proven its capabilities in bringing many benefits to products including improved fiber uniformity, reduced water amount in the process, reduced drying energy due to both reduced water amount and surface tension, improved capability of handling an extremely long or short fiber that enables an introduction of long staple fiber and very short fiber fine into a regular wet laying process, and enhanced bulk/reduced density that broadens one process to be able to produce various materials from a high to a very low density to cover multiple product applications.

Bench experimentation using a high speed mixer and surfactant has produced a very low density, between 0.008 to 0.02 g/cc, foam-formed fibrous materials. Based on these results, an air-formed, 3D-structured, nonwoven-like fibrous material can be produced using a low cost but high speed wet laying process. Previous attempts to produce such low density fibrous materials using typical foam-forming lines did not produce favorable results. Both processes have equipment limitations preventing production of a low density or high bulk foam-formed fibrous material. One process lacks a drying capability and therefore must use a press with high pressure to remove water from a formed wet sheet as much as possible to gain wet sheet integrity, so the sheet can be winded onto a roll. In addition, another process does not have a pressure roll but has a continuous drying tunnel. While the latter process appears to have a potential to produce a low density fibrous material, the foam-formed wet sheet must be transferred from a forming fabric to a drying metal wire before it is dried inside the drying tunnel. Again, to gain enough wet sheet integrity for this transfer, the foam-formed sheet must be dewatered as much as possible by vacuum prior to this transfer. As a result, most of entrapped air bubbles inside the wet sheet are also removed by the vacuum, resulting in a final dried sheet with a density similar to that of a sheet produced by a normal wet laying process.

The latter process includes a foam-forming line that is designed to handle long staple fiber and is capable of achieving very uniform fiber mixing with other components. It is not, however, designed for producing high bulk fibrous material due to its equipment limitations as discussed above. Fig. 1 illustrates the difficulty in using this process to produce high bulk fibrous material, where a sheet is transferred between two wires. In this pilot line, a frothed fibrous material 20 is formed onto a forming wire 30 by a headbox 35, where the material 20 has a high bulk when it is just laid onto the forming wire 30. The material 20 is then subjected to a high vacuum to remove as much of water as possible so that when the wet sheet 20 travels to the end of the first forming wire 30, it gains enough integrity or strength to allow the sheet 20 to be shifted to a drying wire 40. There is an air gap 50 between the forming and drying wires 30, 40 where the sheet 20 forms a bridge 60 between the forming and drying wires 30, 40. Reducing the vacuum level to keep a certain amount of water in the wet sheet 20 can allow the sheet to retain a sufficient amount of frothed air bubbles to enhance its bulk. In this method, however, the wet sheet 20 formed did not have sufficient strength to form the bridge 60 at the location shown in Fig 1 . As a result, a modified process or a new fibrous composition is needed to produce an open structure, high bulk material even with the removal of as much water as possible.

Further experimentation resulted in the discovery that an addition of as little as 20% crimped staple fiber reduces the final fibrous sheet density as much as nearly 50%. Fig. 2 demonstrates such an improvement in maintaining wet sheet thickness. Fig. 2A shows total wet sheet bulk without crimped fiber collapsing along a dewatering vacuum line 80, while Fig. 2B shows only a slightly reduction in sheet thickness, due to presence of a crimped fiber.

Without committing to a theory, it is believed that the crimped fiber that acts as many rigid springs inside the foam-formed wet fibrous sheet to keep the fibrous structure open even after a complete removal of both water and entrapped air bubbles. Because of this, the crimped fiber length, diameter, crimped structure (i.e., 2D vs. 3D crimped shapes), polymer type, and crimped fiber amount are all factors affecting density or bulk of a foam- formed fibrous material.

According to the present disclosure, the foam-forming process is combined with a unique fiber addition for producing webs having a desired balance of properties.

In forming tissue or paper webs in accordance with the present disclosure, in one aspect, a foam is first formed by combining water with a foaming agent. The foaming agent, for instance, can include any suitable surfactant. In one aspect, for instance, the foaming agent can include an anionic surfactant such as sodium lauryl sulfate, which is also known as sodium laureth sulfate and sodium lauryl ether sulfate. Other anionic foaming agents include sodium dodecyl sulfate or ammonium lauryl sulfate. In other aspects, the foaming agent can include any suitable cationic, non-ionic, and/or amphoteric surfactant. For instance, other foaming agents include fatty acid amines, amides, amine oxides, fatty acid quaternary compounds, polyvinyl alcohol, polyethylene glycol alkyi ether, polyoxyethylene soritan alkyi esters, glucoside alkyi ethers, cocamidopropyl hydroxysultaine, cocamidopropyl betaine, phosphatidylethanolamine, and the like.

The foaming agent is combined with water generally in an amount greater than about 0.001 % by weight, such as in an amount greater than about 0.005% by weight, such as in an amount greater than about 0.01 % by weight, or such as in an amount greater than about 0.05% by weight. The foaming agent can also be combined with water generally in an amount less than about 0.2% by weight, such as in an amount less than about 0.5% by weight, such as in an amount less than about 1.0% by weight, or such as in an amount less than about 5% by weight. One or more foaming agents are generally present in an amount less than about 5% by weight, such as in an amount less than about 2% by weight, such as in an amount less than about 1 % by weight, or such as in an amount less than about 0.5% by weight.

Once the foaming agent and water are combined, the mixture is combined with a fiber furnish. In general, any fibers capable of making a tissue or paper web or other similar type of nonwoven in accordance with the present disclosure can be used.

Fibers suitable for making tissue webs include any natural and/or synthetic fibers. Natural fibers can include, but are not limited to, nonwoody fibers such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; and woody or pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; and hardwood fibers, such as eucalyptus, maple, birch, and aspen. Pulp fibers can be prepared in high-yield or low-yield forms and can be pulped in any known method, including kraft, sulfite, high-yield pulping methods, and other known pulping methods. Fibers prepared from organosolv pulping methods can also be used.

A portion of the fibers, such as up to 50% or less by dry weight, or from about 5% to about 30% by dry weight, can be synthetic fibers such as rayon, polyolefin fibers, polyester fibers, bicomponent sheath-core fibers, multi-component binder fibers, and the like. An exemplary polyethylene fiber is FYBREL polyethylene fibers available from Minifibers, Inc. (Jackson City, Tenn.). Any known bleaching method can be used. Regenerated or modified cellulose fiber types include rayon in all its varieties and other fibers derived from viscose or chemically-modified cellulose. Chemically treated natural cellulosic fibers can be used such as mercerized pulps, chemically stiffened or crosslinked fibers, or sulfonated fibers. For good mechanical properties in using papermaking fibers, it can be desirable that the fibers be relatively undamaged and largely unrefined or only lightly refined. While recycled fibers can be used, virgin fibers are generally useful for their mechanical properties and lack of contaminants. Mercerized fibers, regenerated cellulosic fibers, cellulose produced by microbes, rayon, and other cellulosic material or cellulosic derivatives can be used. Suitable papermaking fibers can also include recycled fibers, virgin fibers, or mixes thereof. In certain aspects capable of high bulk and good compressive properties, the fibers can have a Canadian Standard Freeness of at least 200, more specifically at least 300, more specifically still at least 400, and most specifically at least 500. Binder fibers can include polyvinyl alcohol (PVA) fibers or any other suitable binder fibers.

Other papermaking fibers that can be used in the present disclosure include paper broke or recycled fibers and high yield fibers. High yield pulp fibers are those papermaking fibers produced by pulping processes providing a yield of about 65% or greater, more specifically about 75% or greater, and still more specifically about 75% to about 95%. Yield is the resulting amount of processed fibers expressed as a percentage of the initial wood mass. Such pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield kraft pulps, all of which leave the resulting fibers with high levels of lignin. High yield fibers are well known for their stiffness in both dry and wet states relative to typical chemically pulped fibers.

Once the foaming agent, water, and fibers are combined, the mixture is blended or otherwise subjected to forces capable of forming a foam. A foam generally refers to a porous matrix, which is an aggregate of hollow cells or bubbles that can be interconnected to form channels or capillaries. The foam density can vary depending upon the particular application and various factors including the fiber furnish used. In one aspect, for instance, the foam density of the foam can be greater than about 200 g/L, such as greater than about 250 g/L, or such as greater than about 300 g/L. The foam density is generally less than about 600 g/L, such as less than about 500 g/L, such as less than about 400 g/L, or such as less than about 350 g/L. In one aspect, for instance, a lower density foam is used having a foam density of generally less than about 350 g/L, such as less than about 340 g/L, or such as less than about 330 g/L. The foam will generally have an air content of greater than about 40%, such as greater than about 50%, or such as greater than about 60%. The air content is generally less than about 80% by volume, such as less than about 75% by volume, or such as less than about 70% by volume.

The tissue web can also be formed without a substantial amount of inner fiber-to-fiber bond strength. In this regard, the fiber furnish used to form the base web can be treated with a chemical debonding agent. The debonding agent can be added to the foamed fiber slurry during the pulping process or can be added directly to the headbox. Suitable debonding agents that can be used in the present disclosure include cationic debonding agents such as fatty dialkyi quaternary amine salts, mono fatty alkyl tertiary amine salts, primary amine salts, imidazoline quaternary salts, silicone quaternary salt, and unsaturated fatty alkyl amine salts. Other suitable debonding agents are disclosed in U.S. Pat. No. 5,529,665 to Kaun, which is incorporated herein by reference. In particular, Kaun discloses the use of cationic silicone compositions as debonding agents.

In one aspect, the debonding agent used in the process of the present disclosure is an organic quaternary ammonium chloride and, particularly, a silicone-based amine salt of a quaternary ammonium chloride. For example, the debonding agent can be PROSOFT TQ1003 debonding agent, marketed by the Hercules Corporation. The debonding agent can be added to the fiber slurry in an amount of from about 1 kg per metric tonne to about 10 kg per metric tonne of fibers present within the slurry.

In an alternative aspect, the debonding agent can be an imidazoline-based agent. The imidazoline-based debonding agent can be obtained, for instance, from the Witco Corporation. The imidazoline-based debonding agent can be added in an amount of between 2.0 to about 15 kg per metric tonne.

Other optional chemical additives can also be added to the aqueous papermaking furnish or to the formed embryonic web to impart additional benefits to the product and process. The following materials are included as examples of additional chemicals that can be applied to the web. The chemicals are included as examples and are not intended to limit the scope of the disclosure. Such chemicals can be added at any point in the papermaking process.

Additional types of chemicals that can be added to the paper web include, but are not limited to, absorbency aids usually in the form of cationic, anionic, or non-ionic surfactants, humectants and plasticizers such as low molecular weight polyethylene glycols and polyhydroxy compounds such as glycerin and propylene glycol. Materials that supply skin health benefits such as mineral oil, aloe extract, vitamin E, silicone, lotions in general, and the like can also be incorporated into the finished products.

In general, the products of the present disclosure can be used in conjunction with any known materials and chemicals that are not antagonistic to its intended use. Examples of such materials include but are not limited to odor control agents, such as odor absorbents, activated carbon fibers and particles, baby powder, baking soda, chelating agents, zeolites, perfumes or other odor-masking agents, cyclodextrin compounds, oxidizers, and the like. Superabsorbent particles can also be employed. Additional options include cationic dyes, optical brighteners, humectants, emollients, and the like.

To form the tissue web, the foam is combined with a selected fiber furnish in conjunction with any auxiliary agents. The foam can be formed by any suitable method, including that described in co-pending U.S. Provisional Patent Application Serial No.

62/437974.

In general, any process capable of forming a paper web can also be utilized in the present disclosure. For example, a papermaking process of the present disclosure can utilize creping, double creping, embossing, air pressing, creped through-air drying, uncreped through-air drying, coform, hydroentangling, as well as other steps known in the art.

The basis weight of tissue webs made in accordance with the present disclosure can vary depending upon the final product. For example, the process can be used to produce bath tissues, facial tissues, paper towels, industrial wipers, and the like. In general, the basis weight of the tissue products can vary from about 6 gsm to about 120 gsm, or such as from about 10 gsm to about 90 gsm. For bath tissue and facial tissues, for instance, the basis weight can range from about 10 gsm to about 40 gsm. For paper towels, on the other hand, the basis weight can range from about 25 gsm to about 80 gsm.

The tissue web bulk can also vary from about 3 cc/g to 20 cc/g, or such as from about 5 cc/g to 15 cc/g. The sheet "bulk" is calculated as the quotient of the caliper of a dry tissue sheet, expressed in microns, divided by the dry basis weight, expressed in grams per square meter. The resulting sheet bulk is expressed in cubic centimeters per gram. More specifically, the caliper is measured as the total thickness of a stack of ten representative sheets and dividing the total thickness of the stack by ten, where each sheet within the stack is placed with the same side up. Caliper is measured in accordance with TAPPI test method T41 1 om-89 "Thickness (caliper) of Paper, Paperboard, and Combined Board" with Note 3 for stacked sheets. The micrometer used for carrying out T41 1 om-89 is an Emveco 200-A Tissue Caliper Tester available from Emveco, Inc., Newberg, Oregon. The micrometer has a load of 2.00 kilo-Pascals (132 grams per square inch), a pressure foot area of 2500 square millimeters, a pressure foot diameter of 56.42 millimeters, a dwell time of 3 seconds and a lowering rate of 0.8 millimeters per second.

In multiple ply products, the basis weight of each tissue web present in the product can also vary. In general, the total basis weight of a multiple ply product will generally be the same as indicated above, such as from about 15 gsm to about 120 gsm. Thus, the basis weight of each ply can be from about 10 gsm to about 60 gsm, or such as from about 20 gsm to about 40 gsm.

A binder fiber can be used to stabilize the foam formed fibrous structure of this invention. A binder fiber can either a thermoplastic bicomponent fiber, such as PE/PET core/sheath fiber, or a water sensitive polymer fiber, such as polyvinyl alcohol fiber.

Commercial binder fiber is usually a bicomponent thermoplastic fiber with two different melting polymers. Two polymers used in this bicomponent fiber usually have quite different melting points. For example, a PE/PET bicomponent fiber has a melting point of 120 °C for PE and a melting point of 260 °C for PET. When this bicomponent fiber is use as a binder fiber, a foam-formed fibrous structure including the PE/PET fiber can be stabilized by exposure to a heat treatment at a temperature slightly above 120 "€so that the PE fiber portion will melt and form inter-fiber bonds with other fibers while the PET fiber portion deliver its mechanical strength to maintain the fiber network intact. The bicomponent fiber can have different shapes with its two polymer components, such as, side-side, core- sheath, eccentric core-sheath, islands in a sea, etc. The core-sheath structure is the most commonly used in commercial binder fiber applications. Commercial binder fibers include T 255 binder fiber with a 6 or 12 mm fiber length and a 2.2 dtex fiber diameter from Trevia or WL Adhesion C binder fiber with a 4 mm fiber length and a 1 .7 dtex fiber diameter from FiberVisions.

A fiber can be mechanically treated to obtain a crimped structure. A crimped fiber exhibits waviness in which the axis of a fiber under minimum external stress departs from a straight line and follows a simple, complex, or irregular wavy path. In its simplest form a crimp is uniplanar and regular, i.e., it resembles a sine wave, but it is frequently much more complicated and irregular. An example of a three-dimensional crimp is a helical crimp. The crimp can be expressed numerically as the number of waves (crimps) per unit length, or as the difference between the distances between two points on the fiber when it is relaxed and when it is straightened under suitable tension, expressed as a percentage of the relaxed distance. One attribute of a crimped fiber that is important to achieve the high bulk of the foam-formed fibrous material of this disclosure is type of polymer from which the fiber is made. For example, a polymer should have a Tg equal to or higher than 0 °C. When a crimped fiber is made of a polymer such as polyethylene (PE), which has a Tg of -125 °C, the fiber is soft even at a room temperature and lacks of enough modulus to keep fibrous structure open under a high external pressure even if it has the right crimped structure. Another attribute of a crimped fiber is fiber diameter. When a crimped fiber is too thin, even if it is made of a polymer having a Tg higher than 0 °C, it may still lack the expansion force needed to keep the structure open. A crimped fiber should have at least 4 dtex in its fiber diameter to contribute to the high bulk enhancement disclosed herein. Suitable crimped fibers include but are not limited to PET or polyester crimped fibers manufactured by Barnet or Mini-Fiber, Inc. having a fiber length about 6 mm and a fiber diameter about 7 dtex, a PTT/PET FIT curled and bowtie shaped fiber from Fiber Innovation Technology having a fiber length about 12 mm and a fiber diameter about 6.5 dtex, and a Nylon crimped fiber from Mini-Fiber, Inc. having a fiber length about 6 mm and a fiber diameter about 13 dtex.

EXAMPLES

Different sets of experiments were conducted to confirm if a crimped staple fiber always contributes to a bulk enhancement or a density reduction for a foam-formed fibrous material. In the first set, a fiber was incorporated into a mixture of wood pulp fiber and a bi- component binder fiber using a bench high speed mixer to generate a very stable foam. This foam-formed fibrous material was cast/dried. Two materials were produced: one with 60% LL 19 wood pulp fiber, 30% PET 6 mm staple fiber without a crimped structure, and 10% Trevira's T 255 bi-component binder fiber (Code A in Table 1 ) ; the other with 60% LL 19, 30% PET 5 mm crimped fiber from MiniFiber Inc., and 10% Trevira's T 255 bi- component binder fiber (Code B in Table 1 ). Both of these two fibrous compositions produced very high bulk sheets with a density below 0.02 g/cc (refer to Codes A and B in Table 1 ).

The frothed foam produced on the bench had a low density because the foam was much more stable and also did not have water removed by a vacuum process. At such a low density, no further reduction in density was demonstrated using a crimped fiber.

The second set produced three codes for comparison. The first of these codes was a control with 60% LL 19, 20% PET 20 mm staple fiber, and 20% T 255 bi-component binder fiber (Code C). The other two codes were produced using crimped fibers. Code D had a 6.3 mm PET crimped fiber from Barnet at 20% crimped fiber, 60% LL 19, and 20% T 255 bi-component binder fiber. Code E had a 6.3 mm PET crimped fiber from Barnet at 80% crimped fiber to replace both 60% LL 19 and 20% PET non-crimped staple fiber in Code C. In both cases using a crimped fiber, a large reduction in density, meaning a large enhancement in bulk, was observed. In comparison to control Code C, Code D had a density reduction almost 50%, even though only 20% of the crimped fiber was used. Adding more crimped fiber could further reduce the density of the sheet, but degree of the reduction was largely reduced. In the Code E use of 80% crimped fiber, the density reduction was about 67% compared to the control Code C. A foam-formed material's density can be reduced when its control material has a density at least above 0.05 g/cc, or preferably at least above 0.08 g/cc. When a control foam-formed fibrous material has a density below 0.02 g/cc, the addition of crimped fiber into the foam-formed fibrous material does not further reduce the density or enhance the bulk of the foam-formed fibrous material.

Table 1 . Foam-formed Codes Produced in Both Bench Study and Pilot Line Trials

Notes: a: LL 19 is a NSWK wood pulp fiber

b: A PET staple fiber with 6 mm fiber length

c: T 255 is a bicomponent binder fiber produced by Trevira with a fiber length of 6 mm and a fiber diameter of 2.2 dtex

d: A polyester crimped staple fiber with a fiber length of 5 mm and produced by MiniFiber Inc.

e: A PET staple fiber with a 20 mm fiber length

f: A crimped PET staple fiber, P60F CR, with a 5 denier & 1/4 inch fiber length and produced by Barnet Figs. 3A-3F illustrate a series of surface SEM pictures for Codes C, D, and E with two magnification levels (15X vs. 120X). The addition of crimped fiber can reduce density significantly. This can be seen again in Figs. 4A-4F, which show a series of cross-sectional SEM pictures for Codes C, D, and E with two magnification levels (15X vs. 120X). In these cross-sectional pictures, one can see both the density of the sheets and also the bulk or thickness of the materials. As the density of the sheet is reduced from Codes C to D due to presence of a crimped fiber, its thickness is also increased. Note that Code D has a much lower basis weight than Code C (90 vs. 140 gsm). If they were at the same basis weight, Code D should be much thicker or have more bulk than Code C.

In further experiments, a foam-forming pilot line trial was conducted to study the effect of both a crimped fiber's chemistry and physical structure on web caliper and density of a foam-formed fibrous sheet. Thirteen samples were produced that included seven different crimped fibers from fiber vendors. Crimped fiber variables included (1 ) Polymer Types, (2) Fiber Lengths, and (3) Fiber Diameters (refer to Table 2 for detailed fiber chemical and physical parameters).

Table 2. Fibers Used for the Foam-forming Trials

Note: Tg data were referenced by Misumi Technical Tutorial (www.misumi- techcentral.com/tt/en/mold/201 1/12/106-glass-transition-temperature-tg-of-plastics.html)

* Fiber diameter conversion: 1 dtex equals to 0.9 denier

Examples 1 -13 in Table 3: The slurries used to form the expanded foams included Triton X-100 as the surfactant. The solids included a combination of a NSBK (Northern Softwood Bleached Kraft) wood pulp fiber, such as LL-19; a synthetic staple fiber having a crimped or non-crimped structure; and the binder fiber Trevira T-255-6 polyethylene/PET sheath/core staple fiber with a 6 mm fiber length and 2 denier fiber diameter. The synthetic staple fibers used have different polymer chemistries and fiber dimensions. These examples were produced on a pilot line. The NBSK wood pulp fiber was pulped in 250 liters of water in a couch pulper. A batch of foam was prepared in the main pulper with the addition of Triton X-100 such that the total system volume (including contents of the couch pulper) would become 4,440 liters of foam with an air content of about 64% of the total volume. The synthetic staple fiber and the binder fiber T-255 were added to the main pulper; this thickstock was supplied to the headbox of a Fourdrinier paper machine at 150 L/minute. The total fiber consistency was 0.45 wt% with the surfactant solid level in the fibrous slurry at 0.15 wt%. A web was formed and allowed to returning to the main pulper via the couch pulper. The NBSK was thus purged from the couch pulper and introduced to the main pulper to complete the furnish. This system was run in closed loop manner for approximately 10 minutes to allow for thickstock and thinstock consistencies, and to allow the grammage to equilibrate. Once it was evident from the control system that the process was stable, the web was taken through a two-zone, electrically heated, through-air dryer. The system was switched from closed loop operation and the excess foam sent to drain such that the thickstock consistency remained constant and the pulper contents were run out. The air temperature in Zone 1 was set to dry the web. The air temperature in Zone 2 was set to 'activate' the bi-component binder fiber to partially melt and bond the fiber matrix together. The dryer conditions were: Zone 1 temperature at 170 to 180 °C and Zone 2 temperature at 150 to 170 °C with the fan speed about 50 to 70%. The products were targeted to achieve a basis weight of 100 gsm. The dry sample was cut into a 10 inch by 10 inch sheet and measured its weight and caliper. The basis weight and density of each product were calculated from the measured values. It was found that when a crimped fiber was effective to generate high bulk, its caliper increased while density reduced. We can use density reduction to define our invention. The density reduction is calculated using the equation below:

Density Change (Dcrimped ^— Dnon-crimped)/Dnon-crimped X

where Ucrimped and Unon-crimped represent web densities of one with a crimped fiber and a non- crimped fiber respectively. Both webs need to contain the same amount of the other fibers. The only difference between the two webs is that one includes a crimped fiber while the other includes a non-crimped fiber.

RESULTS

Referring to polymer type in Table 3, a wide range of different polymer types of crimped fibers from PET, nylon, acrylic, PTT/PET, and PE were run. A crimped fiber is preferably made of a "stiff" polymer in to be effective to generate bulk. For example, when a crimped fiber made of polyethylene polymer (PE), even though it has a fiber diameter of 6 deniers and is therefore thick enough, the PE fiber lacks the capability to generate bulk due to its softness, especially at an elevated temperature during the process (refer to Code 8 in Table 3). Fiber softness or stiffness can be defined using the fiber's glass transition temperature, Tg. The higher the Tg, the more stiff the polymer or fiber is. In general, a suitable crimped fiber should be made from a polymer having a Tg equal to or greater than 0 °C. PE has a Tg of -125 °C, while PP has a Tg of 0 °C.

In addition, crimped fibers having a wide range of fiber lengths from 6 mm to 60 mm were used. The pilot line, however, could only handle fibers with lengths less than 30 mm. As a result, the upper limit of useful fiber lengths was not determined. Crimped fibers up to 60 mm, however, should be usable if they can be uniformly dispersed in a foam-formed fibrous sheet, and should be able to generate bulk.

Further, experimentation with different fiber diameters determined that fiber diameter is a key variable. Crimped fibers with a diameter less than 3 deniers were found to be ineffective in terms of bulk enhancement. Therefore, not all crimped fibers, even those with a Tg above 0 °C, are effective in delivering the desired bulk enhancement. For example, in a comparison between Codes 5 and 6 in Table 3, a crimped acrylic fiber having a 15 deniers fiber diameter was more effective to generate wet bulk (or reduce web density) than the fiber having only a 1 .5 deniers fiber diameter.

Finally, the crimped structure was varied in the experiments. The bulk enhancement benefit in a foam-formed fibrous sheet including a crimped fiber as opposed to one including a non-crimped fiber was determined. Two fibrous web compositions were used: (1 ) a web containing only 20% crimped fiber vs. 20% non-crimped fiber, and (2) a web containing 80% crimped fiber vs. 80% non-crimped fiber. In general, the greater the proportion of crimped content used, the higher the enhancement in caliper or the more the reduction in density of the fibrous sheet can be seen. Table 3. Properties of Foam-formed Fibrous Sheets

^* Density Change = (Density of Web - Density of Control Web)/Density of Control Web X 100%.

In a first particular aspect, a method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 1 % by weight crimped synthetic fibers and at least 1 % by weight binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate.

A second particular aspect includes the first particular aspect, wherein the foam- formed substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

A third particular aspect includes the first and/or second aspect, wherein the crimped synthetic fibers have a length from 5 mm to 60 mm.

A fourth particular aspect includes one or more of aspects 1 -3, wherein the crimped synthetic fibers have a length from 5 mm to 30 mm.

A fifth particular aspect includes one or more of aspects 1 -4, wherein the crimped synthetic fibers have a diameter of at least 4 dtex.

A sixth particular aspect includes one or more of aspects 1 -5, wherein the crimped synthetic fibers have a three-dimensional kinked or curly structure.

A seventh particular aspect includes one or more of aspects 1 -6, wherein the crimped synthetic fibers include a polymer having a Tg greater than or equal to 0 °C.

An eighth particular aspect includes one or more of aspects 1 -7, wherein the foam- formed substrate exhibits at least a 30% reduction in density compared to the same foam- formed substrate with non-crimped fiber replacing the crimped fiber.

A ninth particular aspect includes one or more of aspects 1 -8, wherein producing includes at least 2% by weight crimped synthetic fibers and at least 2% by weight binder fibers.

A tenth particular aspect includes one or more of aspects 1 -9, wherein producing includes at least 5% by weight crimped synthetic fibers and at least 5% by weight binder fibers.

An eleventh particular aspect includes one or more of aspects 1 -10, wherein the foam-formed substrate is free of superabsorbent material.

A twelfth particular aspect includes one or more of aspects 1 -1 1 , wherein the crimped fiber has a fiber length from 5 to 30 mm, a fiber diameter of at least 4 dtex, and include a polymer having a Tg greater than or equal to 0 °C.

In a thirteenth particular aspect, a substrate includes an aqueous-based polymer foam including at least 1% by weight crimped synthetic fiber and at least 1% by weight binder fiber, wherein the substrate is free of superabsorbent material.

A fourteenth particular aspect includes the thirteenth particular aspect, wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

A fifteenth particular aspect includes the thirteenth and/or fourteenth particular aspects, wherein the crimped synthetic fibers have a length from 5 mm to 30 mm.

A sixteenth particular aspect includes one or more of aspects 13-15, wherein the crimped synthetic fibers have a diameter of at least 4 dtex.

A seventeenth particular aspect includes one or more of aspects 13-16, wherein the crimped synthetic fibers include a polymer having a Tg greater than or equal to 0 °C.

An eighteenth particular aspect includes one or more of aspects 13-17, wherein the crimped fiber has a fiber length from 5 to 30 mm, a fiber diameter of at least 4 dtex, and include a polymer having a Tg greater than or equal to 0°C.

A nineteenth particular aspect includes one or more of aspects 13-18, wherein producing includes at least 2% by weight crimped synthetic fibers and at least 2% by weight binder fibers.

In a twentieth particular aspect, a method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 2% by weight crimped binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate, wherein the foam-formed substrate is free of superabsorbent material, and wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

These and other modifications and variations to the present disclosure can be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present disclosure, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various aspects of the present disclosure may be interchanged either in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the disclosure so further described in such appended claims.