Embossing Press-Dried Tissue Paper With Varying Depth
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Solution Overview
Problem
The energy-intensive Through Air Drying (TAD) process for producing tissue paper with advantageous mechanical and haptic properties is inefficient, and existing press-drying methods result in tissue paper without structure, lacking the desirable softness and absorption capacity of TAD-produced paper.
Innovation Solution
A method involving embossing press-dried tissue paper with an embossing element having a textured surface with varying embossing depths to introduce a fine structure, mimicking the structure of a TAD system, which can be done using an embossing roller or part of a processing machine, allowing for energy-neutral improvement of tissue paper properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the blow-through drying process (TAD) is used to produce tissue paper, then the tissue paper exhibits advantageous mechanical and haptic properties including softness and increased volume, but the process is significantly more energy-intensive
Solution Approach 1:
The invention separates the structuring function from the drying function. Instead of using the complex TAD process where hot air blows through the paper, the patent applies a separate embossing step that imprints a mesh-like structure onto press-dried paper, achieving the desired softness and volume without the energy-intensive drying process
Solution Approach 2:
The embossing element creates a copy of the TAD mesh structure on the tissue paper surface. By embossing a pattern that mimics the three-dimensional network structure formed in TAD processes, the invention reproduces the softness and absorbency characteristics without requiring the actual TAD process
2Ease of manufacture
If the Yankee cylinder press drying process is used, then the tissue paper has a smooth surface without structure, but it lacks the softness and absorbency of TAD-produced paper
Solution Approach 1:
The embossing step is applied after press drying to create the fine structure. By first drying the paper efficiently using press drying and then adding the structural features through embossing, the invention achieves both manufacturing efficiency and the desired softness characteristics
3Quantity of substance
If the blow-through drying process is used, then the tissue paper exhibits increased volume and surface area improving absorbency, but the process is significantly more energy-intensive
Solution Approach 1:
The embossing element creates localized three-dimensional structures with varying heights on the tissue paper surface. This local structuring increases the effective surface area and volume in specific regions, enhancing absorbency without requiring the global structural changes achieved through TAD 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
This method effectively introduces the advantageous material properties of TAD-produced tissue paper into press-dried tissue paper, enhancing softness and absorption capacity without the energy-intensive TAD process, while allowing for the production of multi-layered products with specific structural elements for gluing points.
Implementation Method 1
embossing the single-ply or multi-ply tissue paper with an embossing element having a structured surface. During embossing, a fine structure is created in the tissue paper, exhibiting an embossing depth that varies along the surface of the tissue paper
Implementation Method 2
a fine structure is created in the tissue paper, exhibiting an embossing depth that varies along the surface of the tissue paper over a plurality of embossing depths, perpendicular to the surface
Data Source
Figure 1
Figure 2.1~2.2
Figure 3
AI summary
The invention relates to a method for producing a structured tissue paper (1) comprising the provision of press-dried single-ply or multi-ply tissue paper (1) and the embossing of the single-ply or multi-ply tissue paper (1) with an embossing element (3) having a structured surface (2), characterized in that during the embossing a fine structure (100) is produced in the tissue paper (1) which has an embossing depth that varies along the surface of the tissue paper over a plurality of embossing depths perpendicular to the surface (2) of the single-ply or multi-ply tissue paper (1).