Embossed Fibrous Structure Absorbency Optimization
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Solution Overview
Problem
Existing paper products struggle to effectively utilize short cellulosic fibers, which are often washed out during the papermaking process, leading to reduced absorbency and wasted processing chemicals, while also requiring improved strength and softness attributes.
Innovation Solution
Incorporating hardwood fibers with specific Runkel Ratio and fiber count, along with embossments, to create a fibrous structure product with enhanced absorbency and strength, utilizing eucalyptus fibers and optimizing the papermaking process to retain short fibers, thereby improving water channeling and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If short cellulosic fibers are used in paper products, then absorbency is improved, but the fibers are washed out during the papermaking process
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of short fibers through specific treatments. The fibers undergo controlled degradation to adjust their size distribution, and chemical treatments are applied to enhance their retention characteristics. This allows the short fibers to maintain their absorbency benefits while overcoming the washout problem through altered fiber parameters.
Solution Approach 2:
The invention uses composite materials by combining short cellulosic fibers with longer fibers and various additives in a controlled slurry mixture. The composite structure allows short fibers to contribute absorbency while being retained within the matrix of longer fibers. The composition includes specific ratios of different fiber lengths and types, along with retention aids and binders that create a stable composite structure.
2Quantity of substance
If short fibers are retained in the papermaking process, then absorbency is improved, but processing chemicals are wasted
Solution Approach 1:
The patent applies local quality by creating zones of different fiber concentrations and properties within the paper structure. Short fibers are selectively distributed to areas where they provide maximum absorbency benefit, while longer fibers provide structural support. This localized arrangement ensures that short fibers are effectively utilized for absorbency without requiring excessive chemical treatments throughout the entire paper matrix, reducing overall chemical waste.
Solution Approach 2:
The invention modifies the chemical parameters of the slurry by adjusting pH, ionic strength, and adding specific retention chemicals that enhance short fiber retention without requiring large amounts of processing chemicals. The chemical environment is optimized to allow short fibers to be retained through electrostatic and physical mechanisms rather than heavy chemical bonding, reducing chemical consumption and waste.
3Quantity of substance
If hardwood fibers with specific Runkel Ratio are used, then water channeling and absorption are improved, but fiber availability and cost are constrained
Solution Approach 1:
The patent applies parameter changes by establishing specific ranges for the Runkel Ratio (0.6 to 1.4) and fiber length (0.5 to 2.0 mm) of hardwood fibers to optimize water channeling and absorption properties. These parameter specifications allow for controlled selection of hardwood fiber sources that meet performance requirements while maintaining flexibility in sourcing from different eucalyptus and hardwood varieties. The defined ranges provide guidance for fiber procurement without restricting to a single fiber source.
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 results in a paper product with improved absorbency and strength, effectively utilizing short fibers and reducing chemical waste, while maintaining desirable softness and absorbency attributes.
Implementation Method 1
Through the selection of the appropriate level, cell wall rigidity, thickness, and shape of the shorter cellulose fibers, an improved paper structure is provided having improved water channeling and absorption effects.
Implementation Method 2
Through the selection of the appropriate level, cell wall rigidity, thickness, and shape of the shorter cellulose fibers, an improved paper structure is provided having improved water channeling and absorption effects.
Data Source
AI summary
A fibrous structure product comprising one or more plies of fibrous structure; a basis weight from about 10 lbs/3000 ft2 to about 50 lbs/3000 ft2; from 16% to about 40% of hardwood fibers, in one embodiment eucalyptus fibers, wherein the starting hardwood fibers have a Runkel Ratio of from 4.5 to about 15 and a fiber count of from about 12 fibers/gram to about 35 fibers/gram; and a Residual Water Value from about 0.001 to about 0.18. In one embodiment the product comprises two or more plies of fibrous structure, a basis weight from about 25 lbs/3000 ft2 to about 50 lbs/3000 ft2 and from about 23% to about 40% of hardwood fibers. In another embodiment at least one of the piles of the fibrous structure product further comprises a plurality of embossments thereon comprising an embossment height of from about 600 μm to about 1,200 μm.