Substrates comprising frothed benefit agents for enhanced substrate benefits
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Solution Overview
Problem
Current methods for applying additive compositions to nonwoven substrates, such as tissue products, face inefficiencies due to low chemical mass efficiency and clogging issues with spray nozzles, which hinder the achievement of enhanced softness and bulk.
Innovation Solution
The use of a frothed polymer chemistry that can maintain structural integrity to reach the dryer surface closer proximity, incorporating additional softness enhancers like microparticles and fibers, resulting in a collapsed foam film layer that increases bulk and softness while reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If spray nozzles are used to apply additive composition to dryer surface, then application coverage is achieved, but chemical mass efficiency is low (40%-70%) due to waste from boundary layer air barrier
Solution Approach 1:
The invention changes the physical state of the additive composition from liquid spray to frothed form (incorporating gas bubbles), which increases viscosity and allows the composition to reach the dryer surface more effectively despite the boundary layer barrier, thereby improving chemical mass efficiency and reducing waste
Solution Approach 2:
The froth structure acts as an intermediary carrier that protects and delivers the additive composition through the air boundary layer more effectively than direct spray, maintaining chemical integrity and reducing loss before reaching the dryer surface
2Ease of operation
If spray nozzles are positioned 4 inches from dryer surface to apply additive composition, then application is feasible, but chemical mass efficiency decreases due to boundary layer air pressure barrier
Solution Approach 1:
Changing the additive composition to a frothed state with increased viscosity enables it to overcome the air pressure barrier at the 4-inch distance more effectively, maintaining delivery efficiency without requiring closer positioning
3Ease of operation
If additional solid particles and short fibers are added to enhance softness, then hand feel is improved, but spray nozzle clogging occurs preventing proper application
Solution Approach 1:
The frothed structure with its gas bubbles and increased viscosity creates a carrier medium that can accommodate solid particles and short fibers without clogging the spray nozzle, enabling delivery of softness-enhancing additives while maintaining nozzle reliability
Solution Approach 2:
The invention creates a composite frothed composition combining liquid additive, gas bubbles, and solid particles/fibers, where the multi-phase structure prevents clogging while delivering all softness-enhancing components effectively
4Volume of stationary object
If creping operation is performed to add bulk to tissue, then softness is increased, but hysteresis and rugosities are increased reducing elasticity
Solution Approach 1:
The frothed additive composition creates a different structural modification during creping that increases bulk through foam expansion rather than mechanical compression, thereby improving softness and bulk without creating the rugosities that reduce elasticity
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
This approach enhances the tactile feel, printing capabilities, and elasticity of nonwoven substrates by improving chemical mass efficiency, reducing waste, and maintaining entrapped air for increased bulk and softness without compromising strength.
Implementation Method 1
a frothed polymer chemistry that can maintain structural integrity to reach the dryer surface closer proximity, incorporating additional softness enhancers like microparticles and fibers, resulting in a collapsed foam film layer
Implementation Method 2
The frothed benefit agents of the present invention have enough structural integrity to reach the dryer surface in closer proximity
Data Source
AI summary
The present invention provides a nonwoven substrate comprising a fibrous web defining a surface; and a layer of a benefit agent wherein said benefit agent is selected from an additive composition, an enhancement component and combinations thereof; wherein said benefit agent is frothed and bonded to the fibrous web surface through a creping process and wherein said nonwoven substrate demonstrates improvements selected from enhanced tactile feel, enhanced printing, a decrease in hysteresis, an increase in bulk, an increase in elasticity/extensibility, an increase in retractability, a reduction in rugosities and combinations thereof when compared to an untreated substrate.