Fibrous Structure with Concentric High-Density Elements
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Solution Overview
Problem
There is a need for cellulosic fibrous structures that offer improved in-use wet state substantiality and durability without compromising dry state tactile feel and absorbency, while also providing enhanced wet state bulk and x-y resistance.
Innovation Solution
A fibrous structure with a repeating concentric pattern of high-density discrete elements, varying in size, is created using a patterned papermaking belt, resulting in a product with a continuous low-density network and discrete high-density regions, enhancing both wet and dry performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high density discrete elements are used to improve wet state substantiality, then wet compression resistance and force to gather are improved, but dry state tactile feel and softness deteriorate
Solution Approach 1:
The fibrous structure implements local quality by creating discrete high-density elements distributed within a low-density matrix. Each high-density element provides localized structural support and compression resistance, while the surrounding low-density regions maintain overall softness and tactile comfort. This spatial differentiation allows the structure to exhibit contrasting properties at different locations simultaneously.
Solution Approach 2:
The structure functions as a composite material system combining two distinct fibrous phases: high-density discrete elements and low-density continuous matrix. This composite architecture enables the integration of conflicting properties - the high-density regions contribute strength and compression resistance, while the low-density regions provide softness and flexibility, achieving a balance that neither phase could accomplish alone.
2Strength
If high density discrete elements are used to improve wet state substantiality, then force to gather is improved, but dry state absorbency deteriorates
Solution Approach 1:
The structure applies local quality by concentrating high-density elements at specific discrete locations rather than uniformly throughout. These localized high-density zones provide the necessary force to gather and structural integrity, while the predominant low-density regions maintain high porosity and capillary action for effective absorbency. The spatial distribution ensures that density enhancements occur only where structural support is needed.
3Ease of manufacture
If uniform fibrous structure is used for manufacturing simplicity, then ease of manufacture is improved, but wet state substantiality and x-y resistance deteriorate
Solution Approach 1:
The manufacturing approach segments the fibrous structure into distinct high-density and low-density regions through a patterned forming process. This segmentation is achieved by applying controlled pressure or using a patterned mold during the wet-laying process, creating a repeating pattern of dense elements within a lighter matrix. The segmented structure provides enhanced x-y resistance and wet substantiality compared to uniform structures, while the systematic nature of the segmentation keeps the manufacturing process relatively simple.
4Strength
If high bulk is used to improve wet state substantiality, then wet compression resistance is improved, but density and structural integrity deteriorate
Solution Approach 1:
The structure employs composite material principles by integrating high-density discrete elements into a low-density fibrous matrix. This composite architecture achieves high bulk and wet compression resistance not through uniform high density, but through the strategic distribution of dense structural elements within a voluminous lighter matrix. The high-density elements act as reinforcement nodes that provide compression resistance, while the overall high bulk is maintained by the extensive low-density regions.
Data Source
AI summary
A fibrous structure includes first, second, and third relatively high density wet-formed discrete elements disposed in a repeating concentric pattern. Each relatively high density wet-formed discrete element is at least partially defined by a continuous relatively low density wet-formed network that extends about an area of the fibrous structure. The first, second, and third relatively high density wet-formed discrete elements are distinguishable one from another by their respective area dimensions.