3D Patterned Fibrous Structure for Sanitary Tissue Cushiness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Sanitary tissue products face a dichotomy where improving surface feel and smoothness negatively impacts cushiness, and vice versa, with existing methods failing to achieve both low average TS7 Emtec values and high compressibility without surface softening agents.
Innovation Solution
The use of 3D patterned fibrous structures with semi-continuous and discrete knuckles, angled greater than 45°, and uncreped surfaces forming the exterior, which create a continuous pillow network for improved surface mobility and cushiness without requiring low slipstick coefficient of friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If surface feel and surface smoothness are increased, then consumer comfort is improved, but cushiness decreases
Solution Approach 1:
The patent applies local quality by creating distinct regions within the fibrous structure - a smooth surface layer for comfort and an underlying compressed core for cushioning. The surface layer is engineered with specific fiber orientation and density to provide smoothness, while the core region maintains higher compressibility for cushioning support.
Solution Approach 2:
The patent transitions from a uniform two-dimensional structure to a three-dimensional multi-layer structure with varying density and compression characteristics. This dimensional change allows simultaneous optimization of surface properties and bulk cushioning properties that cannot be achieved in a homogeneous structure.
2Ease of operation
If surface feel is improved (lower TS7 values), then surface mobility is enhanced, but compressibility deteriorates
Solution Approach 1:
The patent segments the fibrous structure into functionally distinct zones - a surface layer optimized for low TS7 values and high mobility, and a bulk layer optimized for compressibility. This segmentation allows each region to be independently optimized without compromising the other property.
Solution Approach 2:
The patent employs parameter changes by varying fiber density, orientation, and compression levels across different regions of the product. The surface layer uses parameters optimized for smoothness (lower density, specific orientation), while the core uses parameters optimized for compression (higher density, random orientation), achieving both low TS7 and high compressibility.
3Strength
If compressibility is increased to provide cushioning, then cushiness is improved, but surface mobility becomes worse
Solution Approach 1:
The patent uses dimensional stratification to separate the functions of cushioning and surface mobility. The bulk three-dimensional structure provides compression and cushioning, while the two-dimensional surface layer provides smoothness and mobility. This dimensional separation resolves the contradiction between bulk and surface properties.
4Ease of operation
If creped surfaces are used to achieve softness, then surface feel improves, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the creping operation from the manufacturing process by using a molded structure that inherently provides the desired surface softness without requiring post-forming creping. This removes the complex creping equipment and process steps while achieving the same surface feel benefits.
Data Source
AI summary
Sanitary tissue products employing fibrous structures that exhibit novel combination of average TS7 values and slip stick coefficient of friction and/or compressibility properties and methods for making same.