Double Embossing Tissue Process for Softness and Strength
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Solution Overview
Problem
Existing tissue paper products often have non-optimal softness and aesthetic features due to conventional embossing processes that prioritize volume over quality and functionality.
Innovation Solution
A double embossing process involving a first embossing station with micro-point cylindrical rollers for tip-to-tip embossing and a second station with undulated rollers for additional embossing, creating a soft and compact tissue paper with a wave pattern, enhancing both functional and aesthetic qualities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional single embossing process is used, then production process is simple, but softness and aesthetic features are non-optimal
Solution Approach 1:
The embossing process is divided into two separate stations: first embossing station with micro-point cylindrical rollers for tip-to-tip embossing, and second embossing station with undulated rollers for wave pattern embossing. This segmentation allows each station to perform a specific function, achieving optimal softness and aesthetic features that cannot be obtained with a single embossing process
Solution Approach 2:
The first embossing station performs preliminary tip-to-tip embossing on the web before it enters the second embossing station. This preliminary action creates a base pattern that enhances the subsequent undulated embossing, resulting in improved softness and absorbency characteristics
2Device complexity
If conventional single embossing process is used, then device complexity is low, but functional features such as absorbency and resistance are insufficient
Solution Approach 1:
The embossing system is segmented into two distinct stations with different roller configurations: the first station uses micro-point cylindrical rollers for tip-to-tip embossing, while the second station uses undulated rollers for wave pattern embossing. This segmentation enables each station to contribute specific functional features, resulting in tissue products with superior absorbency and resistance to breaking and tearing
Solution Approach 2:
The double embossing process creates a composite structure within the tissue web by combining two different embossing patterns (tip-to-tip and undulated wave patterns). This composite structure enhances the functional features of the tissue, including absorbency and mechanical strength, by creating a more complex and effective fiber arrangement
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 process results in tissue products with improved softness, absorbency, resistance to breaking and tearing, and a luxurious feel, making them suitable for high-end applications such as luxury hotels and events, surpassing the quality of standard tissue papers.
Implementation Method 1
a first embossing station composed of two opposing cylindrical rollers, both having in relief micro-points one close to the other, suitable for performing a first tip-to-tip embossing
Implementation Method 2
two opposing cylindrical rollers characterised by undulated reliefs suitable for performing a second undulated embossing on said previously embossed web
Data Source
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AI summary
A description is given of a process for producing a product in tissue paper from a web (21) formed by two or more layers, comprising the steps consisting of: loading a reel (20) of said multilayer web (21) made up of overlapping layers (21a, 21b, 21c) in a loading and unwinding station (1); unwinding the reel (20) to feed the web (21) to a first embossing station (3) composed of two opposing cylindrical rollers (13, 23) both having micro-points close one to the other in relief, suitable for performing a first embossing of the tip-to-tip type; wherein said web (21) in output from the first embossing station (3) is fed to a second embossing station (4) composed of two opposing cylindrical rollers (14, 24) characterised by undulated reliefs suitable for performing a second undulated embossing on said previously embossed web (21).