Co-Formed Fibrous Structures for Low-Modulus Embossed Tissue
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Solution Overview
Problem
There is a need for fibrous structures that exhibit a Geometric Mean Modulus (GM Modulus) of less than 1070 g/cm and/or a Geometric Mean Elongation (GM Elongation) of less than 15%, which are not currently available in the market, particularly for single-ply, embossed sanitary tissue products.
Innovation Solution
The development of fibrous structures with specific properties, including a GM Modulus of less than 1070 g/cm and a GM Elongation of less than 15%, achieved through the use of co-formed structures comprising polypropylene filaments and wood pulp fibers, and processes such as wet-laid papermaking, which allow for the creation of embossed fibrous structures with desired mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fibrous structures are used, then manufacturing simplicity is maintained, but the GM Modulus exceeds 1070 g/cm and GM Elongation exceeds 15%, failing to meet consumer desires for softer, more flexible products
Solution Approach 1:
The patent employs composite materials by combining wood pulp fibers with thermoplastic binder fibers in a co-formed structure. This composite approach enables the fibrous structure to achieve a GM Modulus below 1070 g/cm while maintaining manufacturability through integrated formation of the fiber matrix and binder distribution during the papermaking process.
Solution Approach 2:
The patent applies parameter changes by controlling the basis weight ratio of wood pulp to binder fibers (binder fibers comprising 5-50% of total basis weight), adjusting fiber length distributions, and modifying formation conditions to achieve the target GM Modulus and GM Elongation properties while maintaining ease of manufacture through standard papermaking processes.
2Stability of the object's composition
If conventional fibrous structures are used, then current manufacturing processes are maintained, but the GM Elongation exceeds 15%, failing to provide the stretch and flexibility consumers desire
Solution Approach 1:
The patent achieves precise control of GM Elongation below 15% by adjusting key parameters including binder fiber content (5-50% of basis weight), fiber length distributions, and formation conditions. These parameter changes enable the fibrous structure to exhibit desired stretch and flexibility while maintaining compositional stability through consistent manufacturing processes.
Solution Approach 2:
The patent applies local quality by creating regions with different binder fiber concentrations and fiber orientations within the fibrous structure. This local variation in composition allows different areas to contribute to overall stretch and flexibility, achieving GM Elongation below 15% while maintaining uniform macroscopic properties.
3Ease of operation
If single-ply embossed structures are created with low GM Modulus and GM Elongation, then consumer-desired softness and flexibility are achieved, but such structures are not currently known in the art
Solution Approach 1:
The patent uses composite materials comprising wood pulp fibers and thermoplastic binder fibers in a co-formed single-ply structure. This composite approach enables the creation of an embossed fibrous structure with GM Modulus below 1070 g/cm and GM Elongation below 15%, achieving consumer-desired softness and flexibility without requiring multi-ply construction.
Solution Approach 2:
The patent applies local quality through embossing that creates regions of varying fiber density and binder distribution within the single-ply structure. This local variation in structure provides enhanced softness and flexibility in specific areas while maintaining overall structural integrity, achieving the desired ease of operation without increasing device complexity.
Data Source
AI summary
Fibrous structures that exhibit a Geometric Mean Modulus (GM Modulus) of less than 1402.4 g/cm at 15 g/cm as measured according to the Modulus Test Method described herein and a Geometric Mean Elongation (GM Elongation or GM Elong) of less than 10.2% measured according to the Elongation Test Method described herein are provided.