Layered Through-Air-Dried Bath Tissue for Softness and Low Lint
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Solution Overview
Problem
Conventional tissue manufacturing methods struggle to produce soft and strong tissues with low lint, as adding binders or softeners to enhance softness often compromises strength, while increasing lint, and existing techniques to reduce lint make tissues less soft.
Innovation Solution
A multi-layer tissue structure is created using through air drying, with an interior layer containing an ionic surfactant as a debonder and a non-ionic surfactant as a softener, along with exterior layers comprising hardwood fibers and wet end additives like dry and temporary wet strength agents, to control fiber bonding and reduce lint without sacrificing softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If binders or softeners are added to enhance softness, then softness is improved, but strength deteriorates
Solution Approach 1:
The patent applies different wet end additives to different layers of the tissue web. The interior layer receives a debonder additive that enhances softness, while the exterior layers receive strength agents. This local differentiation allows the tissue to achieve softness where needed without compromising overall strength.
Solution Approach 2:
The tissue is divided into multiple layers with distinct functional assignments. The interior layer is optimized for softness through debonder additives, while exterior layers are optimized for strength. This segmentation allows independent optimization of conflicting properties in different regions.
2Object-generated harmful factors
If lint reduction techniques are applied, then lint is reduced, but softness deteriorates
Solution Approach 1:
The patent applies different wet end additives to different layers of the tissue web. The interior layer receives a debonder additive that enhances softness, while the exterior layers receive strength agents. This local differentiation allows the tissue to achieve softness where needed without compromising overall strength.
Solution Approach 2:
The patent changes the chemical parameters of the wet end additives to achieve both lint reduction and softness. By selecting specific debonder additives with appropriate chemical properties, the invention reduces lint while maintaining softness, overcoming the traditional trade-off.
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 method results in a soft structured tissue with low lint levels, achieving a softness of 91 HF and a lint value of 5.0 or less, while maintaining strength and integrity.
Implementation Method 1
The interior layer includes a first wet end additive comprising an ionic surfactant and a second wet end additive comprising a non-ionic surfactant
Implementation Method 2
The interior layer includes a first wet end additive comprising an ionic surfactant and a second wet end additive comprising a non-ionic surfactant
Implementation Method 3
An object of the present invention is to provide a tissue manufacturing method that uses through air drying to produce a tissue with exceptional softness and low lint
Data Source
AI summary
A multi-ply through air dried structured tissue having a bulk softness of less than 10 TS7 and a lint value of 5.0 or less. Each ply of the tissue has a first exterior layer that includes a wet end temporary wet strength additive in an amount of approximately 0.25 kg/ton and a wet end dry strength additive in an amount of approximately 0.25 kg/ton, an interior layer that includes a first wet end additive comprising an ionic surfactant, and a second wet end additive comprising a non-ionic surfactant, and a second exterior layer.