CWP Tissue Embossing Pattern for Softness
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Solution Overview
Problem
Conventional wet press (CWP) tissue products lack the softness and handfeel of through-air-drying (TAD) products, which are more expensive and bulkier, making it difficult for manufacturers to achieve similar absorbency and softness characteristics without increasing capital and energy costs.
Innovation Solution
An embossing pattern featuring petal-elements that form pillow zones on a CWP base sheet, providing improved handfeel without significant increases in caliper or bulk, achieved through a method that includes embossing with a series of repetitive elements where two petal elements from adjacent emboss elements form one side of a pillow zone, spaced between 0.005 inches to 0.050 inches apart, and a ratio of pillow zone length to emboss element distance from 2:1 to 60:1.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wet press (CWP) methods are used to produce tissue products, then capital and energy costs are reduced, but the softness and handfeel of the product deteriorate compared to TAD products
Solution Approach 1:
The patent applies parameter changes by modifying the embossing process parameters including using a specific embossing pattern with petal elements, controlling embossing depth, and adjusting the spacing between emboss elements to create pillow zones that improve handfeel without changing the fundamental CWP manufacturing method
Solution Approach 2:
The patent implements local quality by creating localized pillow zones through specific embossing patterns that concentrate softness improvements in targeted areas where petal elements form compressed zones, rather than uniformly treating the entire tissue sheet
2Ease of operation
If through-air-drying (TAD) methods are used to produce tissue products, then softness and handfeel are improved, but caliper and bulk increase significantly
Solution Approach 1:
The patent uses parameter changes by controlling the embossing depth and pattern density to create the perception of bulk through surface topology rather than actual volume increase, allowing softness improvement without significant caliper increase
Solution Approach 2:
The patent applies an analogous principle by creating visual and tactile perception changes through embossing patterns that make the tissue appear and feel softer without actually increasing its physical bulk, similar to how visual cues can affect perception
3Ease of operation
If through-air-drying (TAD) methods are used to produce tissue products, then softness and handfeel are improved, but package size increases requiring larger packaging or reduced product count
Solution Approach 1:
The patent applies parameter changes by using embossing pattern density and pillow zone dimensions as control parameters to achieve softness improvement while maintaining compact form factor suitable for existing packaging configurations
4Volume of stationary object
If conventional embossing processes are used to improve bulk, then the perceived puffiness is improved, but the physical handfeel and softness do not significantly improve
Solution Approach 1:
The patent implements local quality by creating differentiated zones within the embossing pattern where petal elements form compressed pillow zones that provide localized softness, rather than using uniform embossing across the entire surface
Solution Approach 2:
The patent applies curvature principles by using petal-shaped emboss elements that create rounded, pillow-like zones, where the curved geometry of the petal elements contributes to the softness perception and tactile comfort
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The embossing pattern significantly enhances the handfeel of CWP products, making them feel softer and more luxurious, while maintaining comparable physical properties and energy efficiency, as demonstrated by side-by-side testing with commercial products.
Implementation Method 1
an embossing method that deforms the paper web in a new way to create pillows that provide significantly improved handfell
Implementation Method 2
The male elements of one emboss roll are engaged or mated with the female elements of another mirror image emboss roll. This method of embossing impacts the aesthetics of the tissue as well as the properties of the tissue sheet
Data Source
AI summary
Products having improved handfeel and methods for making those products are described. The disclosed napkin product includes an emboss pattern that creates a pillow effect resulting in improved handfeel.