Fibrous structures and methods for making same
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Solution Overview
Problem
Existing fibrous structures and sanitary tissue products face challenges in achieving improved softness and better sheet control during papermaking, with previous designs often resulting in nubs that negatively impact consumer experience and sheet width stability.
Innovation Solution
The development of fibrous structures with a surface pattern featuring a continuous knuckle region and a plurality of discrete pillow regions, where the pillow regions are dispersed within the knuckle region, and specific dimensions and properties are defined to enhance softness and sheet control, such as uniform width, orientation, and density, using patterned molding members like through-air-drying belts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a continuous pillow network with discrete knuckles is used in the molding member, then a surface pattern is formed, but nubs are created that reduce softness
Solution Approach 1:
The patent inverts the traditional continuous pillow network with discrete knuckles configuration to a continuous knuckle network with discrete pillows configuration. This inversion eliminates the formation of nubs while maintaining the surface pattern, as the discrete pillows are contained within the continuous knuckle network rather than the other way around.
Solution Approach 2:
The patent applies local quality by creating discrete pillow regions with specific properties (lower density, different fiber composition) within the continuous knuckle network. This allows different regions to have different characteristics - the continuous knuckle regions provide structural integrity while the discrete pillow regions provide softness without forming nubs.
2Shape
If discrete knuckles are used in the molding member, then a surface pattern is created, but sheet control and width stability deteriorate
Solution Approach 1:
The patent inverts the configuration from discrete knuckles in a continuous pillow network to discrete pillows in a continuous knuckle network. The continuous knuckle network provides structural support and maintains sheet width stability during papermaking, while the discrete pillows create the desired surface pattern without compromising sheet control.
Solution Approach 2:
The continuous knuckle network provides localized structural support throughout the molding member, ensuring uniform sheet width stability across the entire sheet width. The discrete pillows are strategically positioned within this stable framework to create the surface pattern without affecting overall sheet control.
3Object-affected harmful factors
If a continuous pillow network is used, then softness is improved, but sheet control during papermaking deteriorates
Solution Approach 1:
The patent creates discrete pillow regions with lower density and higher softness characteristics, surrounded by a continuous knuckle network that provides structural stability. This local differentiation allows the pillow regions to contribute to softness while the knuckle network maintains sheet control during papermaking operations.
Solution Approach 2:
The molding member creates a composite fibrous structure with two distinct regions: continuous knuckle regions with higher density and structural properties, and discrete pillow regions with lower density and softer properties. This composite structure achieves both softness and sheet control simultaneously.
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 exhibit improved softness compared to known fibrous structures and better sheet control during the making of such fibrous structures are provided.