Embossed Fibrous Tissue Structures With Heat-Set Visible Patterns

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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-efficient, but the embossments relax and become less visible to consumers

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 elevated levels (typically 100-200°C). This thermal parameter change enables the embossments to set permanently in filament-based fibrous structures without relaxing, thereby improving visibility while accepting increased energy consumption as a necessary trade-off for achieving permanent embossment formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The heated embossing roll induces phase transitions in the filament materials (melting, softening, or gelation) during the embossing process. This phase change allows the filaments to flow and conform to the embossing pattern, creating permanent visible embossments that maintain their shape without relaxation, directly addressing the visibility issue

Inventive Principle:

Principle #36Phase transitions

2Stability of the object's composition

If steam is applied to reduce modulus of fibrous structures prior to embossing (as in cellulosic pulp), then the embossing process becomes more complex, but the embossments become more permanent

Engineering Contradiction:

Improvepermanency of embossmentsVSAvoidcomplexity of embossing process

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the steam application step from the embossing process for filament-based fibrous structures. By removing this preliminary treatment step, the process complexity is reduced while maintaining permanent embossment formation through the use of heated embossing rolls alone, which directly heat and set the embossments without requiring prior moisture softening

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical/chemical softening approach (steam application to reduce modulus) with a direct thermal embossing approach. The heated embossing roll provides both the heat needed to soften the filaments and the pressure needed to form permanent embossments in a single integrated step, eliminating the need for separate steam treatment and reducing overall process complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If thermal bonds are imparted to fibrous structures comprising filaments, then the structural integrity is improved, but the embossments may merge with thermal bonds and lose definition

Engineering Contradiction:

Improvestructural integrity of fibrous structureVSAvoiddefinition of embossments

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent segments the embossing process into distinct zones or patterns on the embossing roll surface, creating discrete embossment features that are spatially separated. This segmentation ensures that individual embossment elements remain defined and visible even as thermal bonds form between filaments, preventing the merging of embossment features while maintaining structural integrity through distributed bonding points

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heated embossing roll applies heat and pressure locally at specific embossment locations rather than uniformly across the entire fibrous structure. This localized thermal treatment creates strong bonds at embossment points while leaving surrounding areas with sufficient filament definition, ensuring both structural integrity at bond points and visual definition of embossment patterns

Inventive Principle:

Principle #3Local quality

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 more permanent embossments that are visible to consumers, enhancing the aesthetic appeal and structural integrity of the products.

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 EffectHeating: Heating

Data Source

PatentUS11673367B2Embossed fibrous structures and methods for making same

Publication Date: 2023.06.13 PROCTER & GAMBLE CO

AI summary

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