Embossed Tissue Ply Layout to Preserve Quilted Bulk
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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
A fibrous structure with a basis weight of 15 g/m2 to 120 g/m2, featuring at least one embossed ply with a surface area comprising 10.0% to 20.0% line embossments, which provides a unique embossment pattern and footprint to enhance consumer appeal while maintaining functional properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If knob-to-knob embossing is used to increase thickness and bulk, then the web exhibits improved aesthetics and increased bulk, but the pillows collapse under pressure during converting and packaging operations, losing the thickness benefit
Solution Approach 1:
The embossing pattern is segmented into discrete pillows rather than continuous compression, creating individual bulk regions that are more resistant to collapse. The pillows are spaced apart and individually supported, preventing the propagation of collapse across the entire web surface during converting and packaging operations.
Solution Approach 2:
The embossing process creates pillows with pre-formed structural support features, including reinforced walls and base structures, before the web enters converting operations. This preliminary structuring ensures the pillows maintain their shape and thickness through subsequent handling, cutting, and packaging processes that would otherwise cause collapse.
2Shape
If nested embossing is used to produce a softer quilted appearance, then the aesthetic quality improves, but the complexity of the embossing process and roll design increases
Solution Approach 1:
Different regions of the embossing rolls are designed with different properties - the male roll features protruding knobs while the female roll features corresponding recesses. This local differentiation creates the quilted appearance through the interaction of these specialized regions, achieving the desired aesthetic while managing roll design complexity through functional specialization rather than uniform complexity across the entire roll surface.
3Volume of moving object
If deep-nested embossing is used to enhance thickness and aesthetic appeal, then the quilted appearance is improved, but the risk of excessive compression and potential damage to the web structure increases
Solution Approach 1:
The embossing process applies compression that is sufficient to create the desired quilted appearance and thickness enhancement, but is controlled to remain below the threshold that would cause web structure damage. The male and female embossing elements are designed with dimensions and spacing that provide adequate compression for aesthetic effect while maintaining web integrity through controlled, partial compression rather than excessive force.
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 thickness, 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
An adhesive material may be applied to the embossed regions of one or both plies to provide additional assurance that the plies will remain in face-to-face contacting relationship
Data Source
AI summary
A fibrous structure having a basis weight ranging from between about 15 g/m2 and about 120 g/m2 and at least one embossed ply having a surface thereof is disclosed. 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 a basis weight ranging from between about 15 g/m2 and about 120 g/m2 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.