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 pillow length to pillow width greater than 1, and a Volume/Area ratio at 1.7 psi greater than 0.05, to enhance cleaning performance and maintain softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous pillow network pattern is used in the molding member, then the fibrous structure achieves a uniform surface pattern, but the Surface Void Volume is insufficient for effective bowel movement cleaning
Solution Approach 1:
The continuous pillow network is segmented into discrete pillow regions separated by knuckle regions. This segmentation creates distinct high-volume pillow areas for cleaning performance while allowing knuckle regions to maintain structural integrity and pattern definition.
Solution Approach 2:
Different regions of the surface pattern are given different properties: pillow regions are designed with higher volume and softer characteristics for cleaning contact, while knuckle regions have lower volume and provide structural support. This local differentiation optimizes both cleaning performance and structural stability.
2Reliability
If the pillow regions are made larger to increase Surface Void Volume, then cleaning performance improves, but the softness of the fibrous structure decreases
Solution Approach 1:
The pillow regions are segmented into discrete units rather than forming a continuous network. This allows individual pillow regions to be optimized for volume and cleaning performance while the spaces between them (knuckle regions) preserve overall sheet flexibility and softness.
Solution Approach 2:
Softness is optimized locally in the knuckle regions that connect pillow regions, while the pillow regions themselves are optimized for volume and cleaning contact. This local quality differentiation allows large pillow regions to improve cleaning without compromising overall sheet softness.
3Manufacturing precision
If discrete knuckles are arranged in a woven pattern at 45 degrees, then the surface pattern is well-defined, but the Surface Void Volume retention is insufficient
Solution Approach 1:
The woven pattern of discrete knuckles is segmented and reconfigured into discrete pillow regions with intervening knuckle regions. This maintains the geometric precision and pattern definition of the woven structure while creating localized high-volume areas that retain Surface Void Volume for cleaning performance.
Solution Approach 2:
The design transitions from a two-dimensional woven pattern to a three-dimensional surface pattern with varying pillow region volumes. This dimensional change allows the surface pattern to maintain precise geometric definition while incorporating volume variations that enhance cleaning performance through retained Surface Void Volume.
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.