Embossed tissue paper products and methods of manufacturing
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Solution Overview
Problem
Conventional embossing techniques result in non-uniform appearance of tissue products due to compressing of embossments when wound into rolls, and previous methods to avoid excessive roll wear and vibrations limit the use of certain embossing patterns.
Innovation Solution
Employing embossing apparatus with male and female elements having shallow sidewall angles and a mismatched geometry, along with a wetting process, to create embossing patterns oriented in the machine or cross-machine direction, reducing roll wear and enabling clearer, visually distinct patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional embossing patterns are used, then the tissue product can be manufactured, but the embossments become non-uniform and compressed when wound into rolls
Solution Approach 1:
The patent applies asymmetry by using male embossing elements with shallow sidewall angles (less than 10 degrees) that do not have symmetric counterparts in the female elements. This asymmetric geometry allows the embossed lines to remain substantially parallel to the machine or cross-machine direction without requiring skewing, thereby maintaining pattern clarity and uniformity when the tissue is wound into rolls.
2Reliability
If embossing elements are skewed by 10 degrees or more to minimize vibrations and roll wear, then roll durability improves, but the embossing pattern clarity deteriorates
Solution Approach 1:
The patent changes the critical parameter of sidewall angle to less than 10 degrees (preferably less than 5 degrees, more preferably about 3 degrees or less). This parameter change enables the embossing elements to be oriented substantially in the machine or cross-machine direction without causing excessive vibrations or roll wear, thereby maintaining both pattern clarity and roll durability simultaneously.
3Ease of manufacture
If dot embossment patterns are used, then the tissue product can be manufactured, but the appearance becomes non-uniform when packaged in roll form
Solution Approach 1:
The patent replaces conventional dot embossments with linear embossing elements that have curved or continuous line patterns. These linear elements with shallow sidewall angles create a more uniform appearance when wound into rolls, as the continuous lines maintain their visual integrity better than discrete dots under compression and curvature.
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
Produces embossed tissue products with improved bulk and pattern clarity, while minimizing roll wear and vibrations, resulting in enhanced product appearance and integrity.
Implementation Method 1
along with a wetting process
Implementation Method 2
a first heatable embossing roll
Data Source
AI summary
Disclosed are embossed, multi-ply tissue products, such as toilet paper or household towel, having embossing patterns with elements oriented substantially in the machine or cross-machine direction. The machine or cross-machine direction oriented elements are preferably line elements and more preferably continuous line elements. The embossing patterns are created using an embossing apparatus and process in which an embossing roll is provided with male elements having relatively shallow side wall angles, such as less than about 5 degrees and heights less than 1.00 mm. The embossing roll is paired with a mismatched counter roll to create an embossing nip therebetween.