Discrete Cell Fibrous Structures for Performance-Aesthetics Balance
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Solution Overview
Problem
Existing fibrous structures face a contradiction between superior product performance and consumer-desired aesthetics, with known knuckle and pillow patterns often failing to achieve both simultaneously.
Innovation Solution
Incorporating discrete knuckle and pillow structures with complex arrangements of distinct regions, formed by papermaking belts and embossing processes, to create fibrous structures with improved properties such as cloth-like feel, bulk, and rapid liquid uptake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional knuckle and pillow patterns are used to improve product performance, then performance properties are enhanced, but consumer-desired aesthetics deteriorate
Solution Approach 1:
The fibrous structure is divided into discrete cells with multiple distinct regions (first, second, third, and fourth regions) within each cell. This segmentation allows different regions to provide different functions - some regions optimized for performance properties like absorbency and strength, while other regions contribute to aesthetic appearance, thereby resolving the contradiction between performance and aesthetics.
Solution Approach 2:
Different regions within the fibrous structure are given different local qualities and properties. The discrete cell structure creates zones with varying characteristics - some areas provide superior performance properties while adjacent areas maintain aesthetic appeal. This local differentiation allows the structure to simultaneously achieve both performance enhancement and visual appeal.
2Shape
If discrete cell structures with complex arrangements are implemented, then both performance and aesthetics are improved, but device complexity increases
Solution Approach 1:
The complex structure is broken down into repeating discrete cell units, each containing multiple distinct regions. This modular segmentation makes the complex structure more manageable and manufacturable, as the same cell pattern can be repeated across the entire fibrous structure using standardized manufacturing processes.
Solution Approach 2:
Multiple distinct regions are combined within a single discrete cell structure, creating a unified unit that integrates both performance-functional regions and aesthetic regions. This merging allows the complex multi-region structure to be manufactured as a single integrated component rather than requiring assembly of separate parts.
Data Source
AI summary
Fibrous structures of the present disclosure may comprise discrete cells comprising one or more legs and/or one or more concavities in certain patterns or Cell Groups. The cells may be discrete knuckles or pillows and may comprise a saddle and at least two legs, where the plurality of discrete wet-formed cells may have a Cell Width, a Saddle Height, a Saddle Width, a Leg Length and a Leg Width, and where the pillow surface has a Distance Between Saddles, a Distance Between Cells, a First Leg Separation Distance, and a Second Leg Separation Distance. A ratio of a Leg Length to a Saddle Height may be between about 1.10 and about 24.0. A ratio of a Distance Between Cells to a Leg Separation Distance may be between about 0.200 and about 10.5.