Embossed Fibrous Structures Permanent Pattern Formation

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Solution Overview

Problem

Embossed fibrous structures comprising filaments, such as polyvinyl alcohol or starch filaments, face consumer acceptance issues due to embossments that relax and become less visible, and existing methods do not effectively create visible embossments in multi-ply sanitary tissue products with polysaccharide filaments.

Innovation Solution

The method involves embossing a multi-ply fibrous structure with a heated emboss roll or passing it through a nip formed by a heated anvil roll and a non-heated emboss roll to create embossed multi-ply sanitary tissue products, ensuring the embossments are more permanent and visible.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If embossing is performed on fibrous structures comprising filaments using conventional non-heated embossing rolls, then the embossing process is simple and energy consumption is low, but the embossments relax and become less visible reducing consumer acceptance

Engineering Contradiction:

Improvevisibility of embossmentsVSAvoidenergy consumption of embossing process

Core Design Contradiction:

Illumination intensityVSUse of energy by stationary object

Solution Approach 1:

The patent applies thermal energy to the embossing roll, changing the temperature parameter from ambient to heated conditions. This thermal parameter change enables the embossments to set permanently in filament-based fibrous structures without relaxation, achieving visible and durable embossing while managing energy consumption through controlled heating.

Inventive Principle:

Principle #35Parameter changes

2Strength

If thermal bonds are applied to filament-based fibrous structures to provide strength and integrity, then the fibrous structure gains strength, but the filaments melt and fuse together which may interfere with embossment formation

Engineering Contradiction:

Improvestrength of fibrous structureVSAvoidembossment formation

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent applies embossing before thermal bonding in the processing sequence. By embossing the fibrous structure first while it is still in a more compliant state, the embossment pattern is established before the filaments undergo melting and fusion during subsequent thermal bonding, thereby preserving both the embossment shape and the strength benefits of thermal bonding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs a multi-stage processing approach with distinct phases: first embossing the fibrous structure, then applying thermal bonding separately. This periodic separation of operations allows each process to occur under optimal conditions without interfering with the other, ensuring both embossment integrity and structural strength.

Inventive Principle:

Principle #19Periodic action

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

This approach results in embossed fibrous structures with enhanced visibility and durability of embossments, addressing the relaxation issue and improving consumer acceptance.

Implementation Method 1

embossing a multi-ply fibrous structure with a heated emboss roll or passing it through a nip formed by a heated anvil roll and a non-heated emboss roll

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Data Source

PatentUS20230256707A1Embossed fibrous structures and methods for making same

Publication Date: 2023.08.17 PROCTER & GAMBLE CO

AI summary

Embossed fibrous structures containing a plurality of filaments and methods for making same are provided.