Fibrous Structure With Irregular Discrete Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fibrous structures, such as sanitary tissue products, often fail to achieve a balance of softness, flexibility, absorbency, and cleaning effectiveness, with existing methods not adequately addressing consumer desires for superior tactile experience and cleaning performance.
Innovation Solution
A method involving the deposition of a pulp fiber slurry onto a Fourdrinier wire, followed by transfer to a forming member with a slower velocity, creating an embryonic web with irregularly shaped discrete elements in an irregular pattern, and subsequent processing steps including de-watering, adhering to a Yankee dryer, creping, and reeling onto a take-up roll, to produce a fibrous structure with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional papermaking methods are used to produce fibrous structures, then manufacturing simplicity is maintained, but the product fails to achieve optimal balance of softness, flexibility, absorbency, and cleaning effectiveness
Solution Approach 1:
The patent applies local quality by creating discrete elements with varying densities (high density and low density regions) within the fibrous structure. These localized density variations provide different functional properties in different areas of the same product, enabling simultaneous achievement of softness (low density regions) and cleaning effectiveness (high density regions) without compromising manufacturing simplicity
Solution Approach 2:
The patent employs asymmetry by forming irregularly shaped discrete elements rather than uniform symmetric structures. This irregular geometry creates varied surface characteristics and density distributions that enhance both tactile softness and cleaning performance while maintaining conventional papermaking processes
2Ease of manufacture
If conventional uniform fibrous structures are produced, then manufacturing process simplicity is maintained, but consumer desired tactile experience (softness, flexibility, cushiony feel) is not achieved
Solution Approach 1:
The patent creates localized regions with different densities within the fibrous structure. Low density regions provide softness and cushiony feel, while high density regions provide structural integrity. This local differentiation of properties achieves superior tactile experience without complicating the overall manufacturing process
Solution Approach 2:
The patent introduces density as an additional dimensional variable beyond the uniform structure. By varying density locally within the same fibrous matrix, the patent creates multi-functional regions that deliver enhanced tactile properties (softness, flexibility, cushiony feel) while maintaining process simplicity
3Ease of manufacture
If conventional fibrous structures are produced, then manufacturing simplicity is maintained, but absorbency and cleaning ability do not meet consumer expectations
Solution Approach 1:
The patent creates high density discrete elements within the fibrous structure that provide enhanced absorbency and cleaning effectiveness in specific locations. These localized high-density regions act as functional zones that improve overall cleaning performance while the rest of the structure maintains manufacturing simplicity
Solution Approach 2:
The patent creates a composite fibrous structure combining high density and low density regions within a single continuous matrix. This composite structure integrates the absorbent and cleaning benefits of high density material with the softness and flexibility of low density material, achieving superior cleaning performance without requiring separate manufacturing processes
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 method results in fibrous structures that are soft, flexible, absorbent, and offer improved cleaning performance, meeting consumer demands for superior tactile experience and cleaning ability.
Implementation Method 1
depositing a slurry of pulp fibers from a headbox of a paper making machine onto a Fourdrinier wire running at a first velocity V1 to form an embryonic web
Implementation Method 2
transferring the embryonic web from the Fourdrinier wire to at least a forming member moving at a second velocity, V2, where the second velocity, V2, is slower than the first velocity, V1
Implementation Method 3
de-watering the embryonic web by through air drying to at least partially dry it
Implementation Method 4
adhering the partially dried web to a Yankee dryer surface for further drying
Implementation Method 5
dry the web to a dry web consistency of at least 92%
Implementation Method 6
creping the dried web off the Yankee dryer
Data Source
AI summary
A method for making a multiply fibrous structure. The method comprising the steps of: depositing a slurry of pulp fibers onto a Fourdrinier wire running at a first velocity V1; transferring the web from the Fourdrinier wire to at least a first molding member moving at a second velocity, V2, slower than the first velocity, V1. The molding member comprises a substantially continuous relatively low density network at least partially defining a plurality of relatively high density, irregularly shaped, discrete elements situated in an irregular pattern. The embryonic web is partially dried, adhered to a Yankee dryer surface, creped from Yankee dryer and reeled at a velocity, V4, that is faster than that (V3) of the Yankee dryer.