Multi-Ply Tissue Embossment Pattern Design for Roll Bulk and Clarity
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Solution Overview
Problem
Conventional embossed tissue products often exhibit non-uniform appearance in roll form due to compression of embossments, affecting their aesthetic appeal and product properties like bulk and softness.
Innovation Solution
The development of multi-ply tissue products with a first ply featuring open, continuous line embossments oriented in the cross-machine direction and a second ply with micro-embossments in a non-registered pattern, enhancing bulk, softness, and embossment clarity, where the embossments on the first ply have a depth of 300 μm or more and the micro-embossments are densely arranged without registration with the first ply's pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional embossing patterns are used, then tissue products gain bulk and softness, but the embossments become non-uniform and compressed when rolled
Solution Approach 1:
The embossment pattern is segmented into two distinct types: macro-embossments (0.5-2.0 mm) providing bulk and softness, and micro-embossments (0.05-0.5 mm) maintaining pattern definition. This segmentation allows each embossment type to fulfill different functional requirements without interfering with each other's performance during rolling.
Solution Approach 2:
Different regions of the tissue product have different embossment characteristics. The macro-embossments are distributed to provide overall bulk and softness, while micro-embossments are positioned to maintain pattern clarity in specific areas. This local differentiation ensures that rolling compression affects different regions differently, preserving overall appearance.
2Ease of operation
If deep embossments are created to improve bulk and softness, then tissue product handfeel improves, but embossment pattern uniformity deteriorates when rolled
Solution Approach 1:
The embossment structure is composite, combining macro-embossments and micro-embossments in a single pattern. The macro-embossments (deeper, larger) provide the handfeel benefits similar to conventional deep embossing, while the integrated micro-embossments (shallower, smaller) compensate for rolling compression effects, maintaining pattern uniformity despite the presence of deep embossments.
3Shape
If embossment density is increased to improve pattern definition, then aesthetic appearance improves, but sheet bulk decreases
Solution Approach 1:
The embossment pattern utilizes two dimensional scales simultaneously: macro-embossments in the larger dimension (0.5-2.0 mm) contributing to sheet bulk and three-dimensional handfeel, and micro-embossments in the smaller dimension (0.05-0.5 mm) providing pattern definition and visual appearance. This multi-dimensional approach allows independent optimization of bulk and pattern definition.
Data Source
AI summary
The embossed multi-ply tissue products have improved bulk, softness, strength, embossment clarity and/or embossment height. The multi-ply tissue products comprise a first tissue ply having a plurality of embossments arranged in an open first pattern such as open, continuous line elements, which may be substantially oriented in the cross-machine direction (CD). The second ply of the multi-ply tissue product have a plurality of micro-embossments disposed in a second pattern. The first and second embossing patterns are such that when the first and second plies are joined to form the product the first and second patterns are not in registration with one another.