Multi-layer Tissue Web with Cotton Fiber Layer
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Solution Overview
Problem
Tissue products face a trade-off between softness and strength, as increasing softness often leads to a decrease in strength, and the use of hardwood fibers for softness is costly and in high demand, necessitating a solution that improves softness without compromising other important properties.
Innovation Solution
Incorporating cotton fibers in limited amounts, specifically in the middle layer of a multi-layered tissue web, which are less than 10% of the total dry weight, to enhance softness without significantly affecting strength, and by strategically placing cotton fibers to avoid contact with the user's skin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hardwood fibers are used to improve softness, then softness is improved, but cost increases and availability decreases due to high demand
Solution Approach 1:
The patent substitutes expensive hardwood fibers with cheaper alternative fibers (such as softwood or recycled fibers) that can achieve the desired softness when combined with cotton fibers, thereby reducing manufacturing cost while maintaining product quality
Solution Approach 2:
The patent creates a composite fiber mixture combining cotton fibers with alternative fibers in specific ratios, producing a blended pulp that achieves softness comparable to hardwood fibers while using more cost-effective and abundant materials
2Shape
If fiber length is reduced to improve softness, then softness is improved, but strength decreases
Solution Approach 1:
The patent optimizes the fiber length parameter by selecting specific fiber length ranges for different fiber types in the mixture, and adjusts the cotton fiber content percentage to achieve the optimal balance between softness and strength
Solution Approach 2:
The patent uses composite fiber structures where cotton fibers are combined with longer alternative fibers to create a synergistic effect that maintains strength while improving softness
Data Source
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AI summary
The disclosure provides a tissue product comprising at least one multi-layered tissue web that includes a first fibrous layer and a second fibrous layer. The first fibrous layer comprises wood fibers and the second fibrous layer comprises cotton fibers. Cotton fibers are present within the second fibrous layer in an amount from about 1 to about 2 percent by weight of the layer, in some embodiments from about 5 to about 20 percent by weight of the layer, and in some embodiments, from about 10 to about 15 percent by weight of the layer. The selective incorporation of cotton fibers in the tissue web results in a web having improved handfeel without negatively effecting strength and durability.