Fibrous structures and methods for making same
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Solution Overview
Problem
Existing fibrous structures and sanitary tissue products fail to retain sufficient Surface Void Volume for effective bowel movement cleaning without compromising softness, as measured by the Surface Void Volume Test Method, Emtec Test Method, and Plate Stiffness Test Method.
Innovation Solution
The development of fibrous structures with a surface pattern featuring a continuous knuckle region and discrete pillow regions, where the pillow regions are oriented at specific angles and exhibit specific dimensions and ratios, such as an average discrete pillow length to width greater than 1 and a perimeter greater than 5 mm, to enhance Surface Void Volume retention and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete knuckles are arranged in a woven pattern with continuous pillow network, then sheet control during manufacturing is improved, but Surface Void Volume retention is insufficient for effective bowel movement cleaning
Solution Approach 1:
The molding member pattern is segmented into distinct discrete knuckle regions and discrete pillow regions, replacing the continuous pillow network. This segmentation allows independent optimization of each region's function while maintaining overall sheet control during manufacturing and sufficient Surface Void Volume retention for cleaning performance.
Solution Approach 2:
Different regions of the fibrous structure are given different properties: discrete knuckle regions provide structural support and sheet control, while discrete pillow regions provide Surface Void Volume for cleaning. This local differentiation resolves the contradiction by assigning specific functions to specific areas rather than using a uniform structure.
2Volume of stationary object
If discrete knuckles are made with larger dimensions, then Surface Void Volume increases for better cleaning, but softness properties deteriorate
Solution Approach 1:
The pillow regions are segmented into discrete, distributed units rather than large continuous areas. This segmentation maintains adequate Surface Void Volume for cleaning while preventing excessive stiffness that would result from large continuous pillow regions.
Solution Approach 2:
The fibrous structure incorporates regions of varying density and void volume - discrete pillow regions with higher void volume for cleaning performance, and discrete knuckle regions with different properties for structural support. This local quality variation allows optimization of both cleaning and softness properties in different areas.
3Ease of manufacture
If discrete knuckles are oriented at 45° with respect to cross-machine direction, then sheet control is improved, but cleaning performance after bowel movements is insufficient
Solution Approach 1:
The pattern is segmented into discrete knuckle regions and discrete pillow regions with specific orientations. The discrete pillow regions are oriented at angles (e.g., 75°) different from the discrete knuckle regions, creating a multi-axial pattern that provides both manufacturing control and adequate cleaning performance.
Solution Approach 2:
The discrete knuckle regions and discrete pillow regions are oriented at different angles asymmetrically with respect to the cross-machine direction. This asymmetric multi-axial orientation optimizes both sheet control during manufacturing and cleaning performance during use.
Data Source
AI summary
Fibrous structures having a surface pattern of a continuous knuckle region and a plurality of discrete pillow regions such that the fibrous structures that retain sufficient Surface Void Volume as measured according to the Surface Void Volume Test Method described herein during use by consumers to provide consumer desirable cleaning performance after bowel movements without providing undesirable negative impacts to softness as measured according to the Emtec Test Method and/or the Plate Stiffness Test Method both described herein, methods for making same, and molding members used in such methods, are provided.