Embossed Tissue Ply Structure for Quilt Bulk Without Pillow Collapse
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Solution Overview
Problem
Existing tissue paper products with embossed designs face challenges in maintaining aesthetic appeal and thickness due to the collapse of pillowed regions under pressure, and existing embossing processes struggle to balance softness, absorbency, drape, and bond strength.
Innovation Solution
The development of a fibrous structure with specific embossment patterns on each ply, where one ply focuses on aesthetics and the other on functional properties, with controlled embossment 'dots' and 'line art' to enhance consumer appeal, and a deep-nested embossing process that coordinates bond strength with softness and drape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If knob-to-knob embossing is used to increase web thickness, then bulk is improved, but the pillowed regions collapse under pressure causing thickness benefit to be lost
Solution Approach 1:
The patent applies nested embossing where embossing elements of one roll mesh between the embossing elements of the other roll, with knobs on one roll contacting the periphery of the other embossing roll. This nested arrangement provides structural support that prevents pillow collapse while maintaining thickness benefits throughout the converting operation and packaging.
2Shape
If nested embossing is used to maintain quilted appearance, then aesthetic quality is improved, but the complexity of coordinating male and female patterns increases
Solution Approach 1:
The patent merges the embossing functions into a single nip between two embossing rolls, where one roll has a male pattern and the other has a female pattern. The patterns are coordinated such that knob crests on the male roll align with low areas on the female roll, providing both aesthetic quilted appearance and structural support in one integrated process.
3Stability of the object's composition
If embossing elements are coordinated to provide support, then structural stability is improved, but the softness and drape of the product may be reduced
Solution Approach 1:
The patent applies local quality by providing support only at specific embossed sites where knobs contact the opposing ply, while leaving other regions of the web uncompressed and soft. This localized support approach maintains structural stability at embossed locations while preserving overall softness and drape of the tissue product.
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 tissue product with improved aesthetic appeal, maintaining a quilted appearance and high caliper, while ensuring softness, absorbency, and bond strength, making it more consumer-preferred.
Implementation Method 1
Embossing elements on the rolls compress and/or deform the web
Implementation Method 2
Embossing elements on the rolls compress and/or deform the web
Implementation Method 3
the embossed sites produced on one ply provide support for the embossed sites on the other ply
Data Source
AI summary
The present disclosure provides for a fibrous structure having an initial total wet tensile strength of greater than about 118 g/cm and at least one embossed ply having a surface thereof. The surface has a surface area comprising from about 10.0 percent to about 20.0 percent line embossments. Also, a fibrous structure having at least two plies is disclosed. One of the two plies has an initial total wet tensile strength of greater than about 118 g/cm and at least one embossed ply having a surface thereof. The surface has a surface area comprising from about 10.0 percent to about 20.0 percent line embossments.