Embossed Multilayer Cellulose Product with Varying Protuberance Heights
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing cellulose products, such as tissue paper, face challenges in optimizing yield while achieving desired aesthetic and functional features, including absorption capacity and tactile qualities, often requiring expensive and energy-intensive processes like TAD systems.
Innovation Solution
A cellulose product comprising at least two plies of embossed cellulose material, with specific series of protuberances of varying heights and distributions, allowing for bonding and embossing patterns that mimic TAD systems' features at reduced costs and energy consumption, using an embossing-laminating device with elastically yielding rollers and targeted glue application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If TAD systems are used to produce cellulose products with enhanced absorption and tactile features, then the functional and aesthetic properties are improved, but the production costs and energy consumption increase significantly
Solution Approach 1:
The patent applies the copying principle by creating an embossed pattern on the cellulose material that replicates the visual and tactile characteristics of TAD systems without requiring the expensive and energy-intensive TAD production process. The embossing roller imparts a pattern of protuberances and cavities that mimics the appearance and absorption properties of TAD-formed tissue, achieving functional similarity at lower cost and energy consumption.
2Reliability
If TAD systems are used to produce cellulose products with enhanced absorption and tactile features, then the functional and aesthetic properties are improved, but the production costs increase significantly
Solution Approach 1:
The patent applies the copying principle by creating an embossed pattern on the cellulose material that replicates the visual and tactile characteristics of TAD systems without requiring the expensive and energy-intensive TAD production process. The embossing roller imparts a pattern of protuberances and cavities that mimics the appearance and absorption properties of TAD-formed tissue, achieving functional similarity at lower cost and energy consumption.
3Reliability
If multiple series of protuberances with varying heights are embossed on cellulose plies, then aesthetic and functional features are enhanced, but the embossing process complexity increases
Solution Approach 1:
The patent applies the segmentation principle by dividing the embossing pattern into multiple distinct series of protuberances with varying heights and distributions. The embossing roller is designed with different zones containing protuberances of different dimensions (first series with larger protuberances, second series with smaller protuberances, and third series with even smaller protuberances), allowing each series to contribute specific aesthetic and functional characteristics to the final product.
Solution Approach 2:
The patent applies the local quality principle by varying the characteristics of protuberances in different local areas of the embossed pattern. Different zones of the embossed surface contain protuberances with different heights, diameters, and distributions, creating localized variations in tactile sensation and absorption properties. This allows specific regions to be optimized for different functions while maintaining overall aesthetic appeal.
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 solution achieves enhanced aesthetic and functional properties similar to TAD systems but with lower costs and energy usage, providing improved absorption, tactile features, and appearance without the need for expensive TAD plants.
Implementation Method 1
one of the two provided with an elastically yielding surface, for imparting a permanent mechanical deformation to the base cellulose material
Implementation Method 2
applying a glue on at least some of the protuberances generated by embossing on at least one of the plies forming the multilayer material
Data Source
AI summary
The cellulose product comprises at least a first ply of embossed cellulose material and a second ply of embossed cellulose material, glued together. The first ply comprises: a first series of embossing protuberances with a first height (H′1) and a top surface to which a glue is applied which bonds the first ply and the second ply to one another; a second series of micro-embossing protuberances with a second height (H′2) lower than the first height (H′1); a third series of micro-embossing protuberances with a third height (H′3) lower than the second height (H′2). The protuberances of the first series are distributed over areas of the first ply, where the micro-embossing protuberances of the second series and the micro-embossing protuberances of the third series are absent.