Fibrous structures and methods for making same
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Solution Overview
Problem
Current fibrous structures, such as paper towels, fail to balance absorption capacity with absorption rate and surface drying properties, as their pore volume distributions do not meet consumer demands for improved absorbency and drying efficiency.
Innovation Solution
Development of fibrous structures comprising filaments and optional solid additives, like wood pulp fibers, with tailored pore volume distributions and surface drying times, where greater than 8% of the total pore volume exists in pores of 2.5 μm to 50 μm and/or achieving a sled surface drying time of less than 50 seconds, achieved through specific manufacturing processes that impart differential densities and textures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If fibrous structures use conventional pore volume distributions, then absorption capacity is optimized, but rate of absorption and surface drying are insufficient
Solution Approach 1:
The patent applies parameter changes by modifying the pore volume distribution parameters of the fibrous structure. Specifically, it creates a non-uniform pore volume distribution with greater than 8% of total pore volume in pores of radii from 2.5 μm to 50 μm, which balances absorption capacity and rate of absorption. This parameter optimization resolves the contradiction between quantity of absorption and speed of absorption.
Solution Approach 2:
The patent implements local quality by creating different pore size regions within the fibrous structure. It ensures that specific regions have pores of radii from 2.5 μm to 50 μm that constitute greater than 8% of total pore volume, while other regions may have different pore characteristics. This localized optimization allows simultaneous improvement of absorption capacity and rate of absorption in different areas.
2Quantity of substance
If fibrous structures optimize absorption capacity, then surface drying time increases, but consumer demand requires faster surface drying
Solution Approach 1:
The patent resolves this contradiction by changing the pore volume distribution parameters to create a balanced distribution. By ensuring greater than 8% of total pore volume exists in pores of radii from 2.5 μm to 50 μm, the structure achieves both high absorption capacity and rapid surface drying (less than 50 seconds), eliminating the trade-off between these two parameters.
Solution Approach 2:
The patent addresses this contradiction by considering pore size distribution across different dimensional scales. It specifically targets the micropore range (2.5 μm to 50 μm radii) to constitute greater than 8% of total pore volume, creating a multi-scale pore structure that simultaneously provides capillary action for rapid surface drying and sufficient volume for high absorption capacity.
3Ease of manufacture
If fibrous structures use uniform pore volume distribution, then manufacturing is simplified, but absorbency properties are insufficient
Solution Approach 1:
The patent applies parameter changes by defining specific pore volume distribution parameters that achieve superior absorbency. By specifying that greater than 8% of total pore volume should exist in pores of radii from 2.5 μm to 50 μm, it creates a reliable, optimized pore structure while maintaining compatibility with conventional manufacturing processes, thus resolving the contradiction between manufacturing ease and performance reliability.
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 resulting fibrous structures exhibit enhanced absorbency and surface drying capabilities, meeting consumer needs by optimizing pore volume distribution and surface drying performance.
Implementation Method 1
greater than 8% of the total pore volume present in the fibrous structures exists in pores of radii of from 2.5 μm to 50 μm
Implementation Method 2
a sled surface drying time of less than 50 seconds as measured by the Sled Surface Drying Test Method
Data Source
AI summary
Novel fibrous structures that contain filaments, and optionally, solid additives, such as fibers, for example wood pulp fibers, sanitary tissue products comprising such fibrous structures, and methods for making such fibrous structures and/or sanitary tissue products are provided.