Fluff pulp and high sap loaded core

Abstract

A fluff pulp is provided, which comprises softwood fibers; and 3 to 35% by weight of hardwood fibers. A fluff is also provided, which comprises the fiberized or shredded fluff pulp. A core is also provided, which comprises the fluff and at least an SAP. Processes for making and using the fluff pulp, fluff, and core are provided, and products made thereby.

What is claimed is: 
     
         1 . A fluff pulp, comprising:
 softwood fibers; and   3 to 35% by weight of hardwood fibers, wherein said pulp having a compressed density, when in the form of a core, of greater than 0.13 g/cm 3  at 161 PSI and a compressed density of greater than 0.18 at 225 PSI.   
     
     
         2 . The fluff pulp of  claim 1 , comprising 5 to 30% by weight of hardwood fibers. 
     
     
         3 . The fluff pulp of  claim 1 , which comprises a moisture content of ≦15% by weight. 
     
     
         4 . The fluff pulp of  claim 1 , which comprises a basis weight of 500 to 1100 gsm. 
     
     
         5 . A process for making fluff pulp, comprising:
 contacting a first aqueous slurry comprising softwood fibers with a second aqueous slurry comprising hardwood fibers, to form a furnish;   contacting the furnish onto a moving wire, to form a web; and   drying and optionally pressing the web, to form the fluff pulp of  claim 1 .   
     
     
         6 . The process of  claim 5 , comprising pressing the web. 
     
     
         7 . The process of  claim 5 , further comprising rolling the fluff pulp onto a roll or cutting the fluff pulp into sheets, and stacking the sheets to form a bale. 
     
     
         8 . The process of  claim 5 , wherein said drying comprises flash drying the web to form the fluff pulp, and thereafter bagging the fluff pulp. 
     
     
         9 . The process of  claim 5 , further comprising contacting the first and second slurries at a blend chest. 
     
     
         10 . The process of  claim 5 , further comprising and prior to contacting the first and second slurries:
 forming the hardwood fibers by one or more steps selected from the group consisting of chipping, pulping, and bleaching hardwood, or a combination of two or more thereof; and   forming the softwood fibers by one or more steps selected from the group consisting of chipping, pulping, and bleaching softwood, or a combination of two or more thereof.   
     
     
         11 . The fluff pulp of  claim 1 , in the form of a bale or roll, or in a bag. 
     
     
         12 . A fluff, comprising the fluff pulp of  claim 1  in fiberized form. 
     
     
         13 . A process for making fluff, comprising fiberizing the fluff pulp of  claim 1 . 
     
     
         14 : The process of  claim 13 , which is carried out in an airlaid line. 
     
     
         15 . The process of  claim 11 , further comprising taking the fluff pulp from a bale, roll, or bag, or combination thereof, and fiberizing. 
     
     
         16 . A core, comprising:
 the fluff of  claim 12  and one or more superabsorbent polymer (SAP).   
     
     
         17 . The core of  claim 16 , wherein the SAP is selected from the group consisting of starch-acrylonitrile copolymer, hydrolyzed starch-acrylonitrile copolymer, acrylic acid (co)polymer, acrylamide (co)polymer, polyvinyl alcohol, polyacrylate/polyacrylamide copolymers, polyacrylic acid (co)polymers, sodium polyacrylate, ethylene maleic anhydride copolymer, cross-linked carboxymethylcellulose, polyvinyl alcohol copolymer, polyethylene oxide, cross-linked polyethylene oxide, starch grafted copolymer of polyacrylonitrile, salt of one or more thereof, and combination of two or more thereof. 
     
     
         18 . The core of  claim 16 , wherein the SAP is present in an amount ranging from 1 to 85% by weight of the core. 
     
     
         19 . A process for making a core, comprising contacting the fluff of  claim 12  and one or more superabsorbent polymer. 
     
     
         20 . The process of  claim 19 , further comprising after the contacting, forming a web, and densifying the web in a nip. 
     
     
         21 . The process of  claim 19 , wherein the contacting is carried out in an airlaid line. 
     
     
         22 . An absorbent product, paper product, personal care product, medical product, insulating product, construction product, structural material, cement, food product, veterinary product, packaging product, diaper, tampon, sanitary napkin, gauze, bandage, fire retardant, or a combination thereof, comprising the core of  claim 13  and a supporting structure. 
     
     
         23 . A process for making the absorbent product of  claim 22 , comprising contacting at least a portion of the core with the supporting structure. 
     
     
         24 . The pulp of  claim 1 , comprising from 5 to 25 wt % of the hardwood fibers. 
     
     
         25 . The pulp of  claim 1 , comprising from 5 to 20 wt % of the hardwood fibers. 
     
     
         26 . The pulp of  claim 1 , comprising 8 to 18 wt % of the hardwood fibers. 
     
     
         27 . The pulp of  claim 1 , having a compressed thickness, when in the form of a core, of less than 280 mil at 161 PSI and a compressed thickness of less than 200 at 225 PSI. 
     
     
         28 . The pulp of  claim 27 , having a compressed density, when in the form of a core, of greater than 0.13 g/cm 3  at 161 PSI and a compressed density of greater than 0.18 at 225 PSI. 
     
     
         29 . The pulp of  claim 1 , having a Gurley Stiffness, when in the form of a core having about 0.31 g/cm 3  density (uncompressed), of less than 1350 mg. 
     
     
         30 . The pulp of  claim 29 , further comprising a debonder. 
     
     
         31 . The pulp of  claim 30 , wherein the debonder comprises at least one debonder selected from the group consisting of a linear or branched monoalkyl amine, linear or branched dialkyl amine, linear or branched tertiary alkyl amine, linear or branched quaternary alkyl amine, ethoxylated alcohol, linear or branched, saturated or unsaturated hydrocarbon surfactant, fatty acid amide, fatty acid amide quaternary ammonium salt, dialkyl dimethyl quaternary ammonium salt, dialkylimidazolinium quaternary ammonium salt, dialkyl ester quaternary ammonium salt, triethanolamine-ditallow fatty acid, fatty acid ester of ethoxylated primary amine, ethoxylated quaternary ammonium salt, dialkyl amide of fatty acid, dialkyl amide of fatty acid, cationic surfactant, non-ionic surfactant, C 16 -C 18  unsaturated alkyl alcohol ethoxylate, compound having CAS Registry No. 68155-01-1, and compound having CAS Registry No. 26316-40-5. 
     
     
         32 . The pulp of  claim 1 , having a Gurley Stiffness, when in the form of a core having about 0.62 g/cm 3  density (uncompressed), of less than 6800 mg. 
     
     
         33 . The pulp of  claim 1 , further comprising a debonder. 
     
     
         34 . The pulp of  claim 33 , wherein the debonder comprises at least one debonder selected from the group consisting of a linear or branched monoalkyl amine, linear or branched dialkyl amine, linear or branched tertiary alkyl amine, linear or branched quaternary alkyl amine, ethoxylated alcohol, linear or branched, saturated or unsaturated hydrocarbon surfactant, fatty acid amide, fatty acid amide quaternary ammonium salt, dialkyl dimethyl quaternary ammonium salt, dialkylimidazolinium quaternary ammonium salt, dialkyl ester quaternary ammonium salt, triethanolamine-ditallow fatty acid, fatty acid ester of ethoxylated primary amine, ethoxylated quaternary ammonium salt, dialkyl amide of fatty acid, dialkyl amide of fatty acid, cationic surfactant, non-ionic surfactant, C 16 -C 18  unsaturated alkyl alcohol ethoxylate, compound having CAS Registry No. 68155-01-1, and compound having CAS Registry No. 26316-40-5.