Multi-Ply Fibrous Structures with Controlled Modulus and Elongation
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Solution Overview
Problem
There is a need for fibrous structures that exhibit a Geometric Mean Modulus (GM Modulus) of less than 1070 g/cm and/or a Geometric Mean Elongation (GM Elongation) of less than 15%, which are not currently available, particularly in single-ply, embossed sanitary tissue products.
Innovation Solution
The development of fibrous structures with a GM Modulus of less than 1070 g/cm and/or a GM Elongation of less than 15%, achieved through specific manufacturing processes that include the use of co-formed structures comprising polypropylene filaments and wood pulp fibers, and embossing techniques to create linear elements with defined dimensions and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fibrous structures are used, then manufacturing simplicity is maintained, but GM Modulus exceeds 1070 g/cm and GM Elongation exceeds 15%
Solution Approach 1:
The patent applies composite materials by combining wood pulp fibers with polypropylene filaments in specific configurations. This composite structure enables precise control of GM Modulus (less than 1070 g/cm) and GM Elongation (less than 15%) while maintaining manufacturability through integrated web formation processes.
Solution Approach 2:
The patent implements local quality through embossed patterns with varying linear element densities and orientations. Different regions of the fibrous structure have tailored properties - some areas with higher linear element density for strength, others with lower density for softness - allowing localized control of mechanical properties to achieve target GM Modulus and GM Elongation values.
2Manufacturing precision
If single-ply embossed structures are created, then product simplicity and cost-effectiveness are maintained, but achieving GM Modulus less than 1070 g/cm and GM Elongation less than 15% is not possible
Solution Approach 1:
The patent applies parameter changes by systematically adjusting embossing parameters including linear element length (0.5-50 mm), width (0.01-2 mm), spacing (0.1-10 mm), and orientation angles (0-90 degrees). These parameter variations enable precise control of GM Modulus and GM Elongation in single-ply structures, achieving the target range while maintaining ease of manufacture through standard embossing equipment.
3Ease of operation
If fibrous structures with lower GM Modulus and GM Elongation are developed, then consumer satisfaction is improved, but such structures are not currently available in the art
Solution Approach 1:
The patent applies dynamics by creating fibrous structures with controlled stretch and recovery characteristics. The linear elements are designed to deform under load and return to original configuration, providing dynamic response that delivers GM Modulus less than 1070 g/cm and GM Elongation less than 15%. This dynamic behavior enhances consumer satisfaction while expanding the available range of fibrous structure performance characteristics.
Data Source
AI summary
Multi-ply fibrous structures that exhibit a Geometric Mean Modulus (GM Modulus) of less than 1700 g/cm at 15 g/cm as measured according to the Modulus Test Method described herein and a Geometric Mean Elongation (GM Elongation or GM Elong) of less than 11.7% measured according to the Elongation Test Method described herein are provided.