Fibrous Structure Overhang Length Control
Solution Overview
Problem
Fibrous structures, particularly sanitary tissue products, often exceed desired Overhang Length values as measured by the Flexural Rigidity Test Method, which can affect their softness, strength, and absorbency.
Innovation Solution
Development of fibrous structures with Geometric Mean Overhang Length (GM Overhang Length) and Cross-Machine Direction Overhang Length (CD Overhang Length) of less than 3.65 cm and 3.875 cm, respectively, achieved through specific manufacturing processes and material combinations, including wet textured and co-formed structures with controlled density and modulus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fibrous structures are used, then manufacturing simplicity is maintained, but Overhang Length exceeds desired values (GM Overhang Length ≥ 3.65 cm and/or CD Overhang Length ≥ 3.875 cm)
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical parameters of the fibrous structure during manufacturing. Specific changes include adjusting the basis weight (20-40 gsm), density (0.04-0.08 g/cm³), and fiber composition ratios to achieve the desired Overhang Length while maintaining manufacturing feasibility
Solution Approach 2:
The patent employs composite materials by combining different fiber types in specific ratios within the fibrous structure. The formulation includes cellulosic fibers (40-70% by weight) combined with alternative fibers such as wood fiber, cotton fiber, or synthetic fibers to create a composite structure that achieves reduced Overhang Length through synergistic material properties
2Manufacturing precision
If Overhang Length is reduced to meet consumer preferences, then product quality improves, but flexibility and softness may be compromised
Solution Approach 1:
The patent applies local quality by creating non-uniform fiber distribution and density patterns within the fibrous structure. By varying the local composition and arrangement of fibers, the structure achieves reduced Overhang Length in specific regions while maintaining flexibility and softness in other areas through localized material property optimization
Solution Approach 2:
The patent uses parameter changes to optimize the balance between Overhang Length reduction and flexibility maintenance. By carefully controlling basis weight (20-40 gsm), density (0.04-0.08 g/cm³), and fiber composition ratios, the patent achieves reduced Overhang Length while preserving the necessary flexibility and softness through optimized material parameters
3Manufacturing precision
If fibrous structure density is increased to reduce Overhang Length, then Overhang Length decreases, but absorbency and comfort are reduced
Solution Approach 1:
The patent employs composite materials by combining cellulosic fibers (40-70% by weight) with alternative fibers that have different density and absorbency characteristics. This composite approach allows the structure to achieve reduced Overhang Length through density optimization while maintaining overall absorbency through the complementary properties of the fiber blend
Solution Approach 2:
The patent applies parameter changes to optimize the balance between density and absorbency. By controlling basis weight (20-40 gsm) and density (0.04-0.08 g/cm³) within specific ranges, and by adjusting fiber composition ratios, the patent achieves reduced Overhang Length while preserving absorbency through optimized material parameters that balance compactness with fluid absorption capacity
Data Source
AI summary
Fibrous structures that exhibit a Geometric Mean Overhang Length (GM Overhang Length) of less than 3.65 cm as measured according to the Flexural Rigidity Test Method and/or a Cross-Machine Direction Overhang Length (CD Overhang Length) of less than 3.875 cm as measured according to the Flexural Rigidity Test Method described herein are provided.