High bulk tissue product
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Solution Overview
Problem
Conventional wet press tissue products exhibit reduced bulk and absorbency due to compaction during the dewatering process, while through-air-drying methods are costly and energy-intensive.
Innovation Solution
An embossing pattern is applied to tissue sheets, increasing the bulk and absorbency of conventional wet press products to levels comparable to through-air-dried webs, using emboss elements with specific aspect ratios and densities, and combining adhesive with decorative patterns for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If conventional wet press dewatering is used, then production cost and energy consumption are reduced, but bulk and absorbency are significantly reduced
Solution Approach 1:
The embossing pattern segments the tissue web into raised elements and recesses, creating a three-dimensional structure that increases bulk without requiring through-air-drying energy input. The pattern divides the continuous web into discrete functional zones
Solution Approach 2:
The embossing process adds vertical dimension to the otherwise flat compressed web. By creating raised elements protruding from the web surface, the invention transforms a two-dimensional compression problem into a three-dimensional structure that restores bulk while maintaining wet press energy efficiency
2Use of energy by stationary object
If conventional wet press dewatering is used, then production cost is reduced, but absorbency is significantly reduced
Solution Approach 1:
The embossing pattern creates a porous surface structure with raised elements and interstitial spaces that enhance liquid absorption capacity. This porous architecture increases absorbency without requiring the high energy input of through-air-drying processes
Solution Approach 2:
By adding vertical relief to the web surface, the embossing creates additional surface area and volume for liquid interaction, thereby increasing absorbency while maintaining cost-effective wet press production
3Volume of stationary object
If through-air-drying is used, then bulk and absorbency are improved, but capital and energy costs increase significantly
Solution Approach 1:
The embossing process creates a physical copy or replica of a three-dimensional pattern on the tissue web surface. This copied structure mimics the bulk characteristics of through-air-dried tissue without requiring the expensive and energy-intensive TAD equipment and process
Solution Approach 2:
The invention replaces the thermal-mechanical through-air-drying system with a mechanical embossing system applied to wet-pressed tissue. This substitution achieves similar bulk outcomes through mechanical pattern formation rather than thermal processing
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 embossing method significantly improves the caliper and absorbency of tissue products, conserving resources and reducing energy consumption, while maintaining softness and aesthetic appeal.
Implementation Method 1
an embossed tissue sheet having improved caliper, bulk and absorbency
Implementation Method 2
adhesive is applied to the tops of the emboss elements of the decorative pattern on the top-most ply, and the plies are bonded
Data Source
AI summary
Products having improved caliper, sheet bulk and absorbency and methods for making those products are described. The method comprises producing a multi-ply product having different emboss patterns on each ply where the emboss patterns are made up of emboss elements having an aspect ratio of from about 1 to about 2.