Multi-ply Tissue Paper with Micro-Embossed Outer Plies
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Solution Overview
Problem
Conventional multi-ply tissue paper products struggle to achieve optimal thickness, softness, bulkiness, absorption capacity, and strength while minimizing the number of plies, which leads to increased paper fiber usage and environmental impact.
Innovation Solution
A multi-ply tissue paper product is designed with at least four plies, where two inner plies are flat and positioned between micro-embossed outer plies, with one outer ply featuring a décor embossing pattern, reducing the surface area of glue application and incorporating an optional core ply for enhanced bonding and structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the number of plies is increased to improve thickness, softness, and bulkiness, then the desired properties are achieved, but paper fiber consumption increases leading to environmental impact
Solution Approach 1:
The patent applies different surface qualities to different plies: outer plies have micro-embossed surfaces providing softness and tactile properties, while inner plies have smooth surfaces. This local differentiation allows achieving desired softness and thickness with fewer plies, reducing paper fiber consumption while maintaining product properties.
2Strength
If adhesive bonding is used to combine plies, then bonding strength is improved, but the surface area required for glue application increases material usage and cost
Solution Approach 1:
The patent applies adhesive only locally at the tips of embossed protuberances rather than over the entire surface. This localized bonding approach maintains sufficient bonding strength while dramatically reducing the surface area requiring glue application, thus reducing adhesive material usage and cost.
Solution Approach 2:
The bonding interface is segmented into discrete bonding points at the embossed protuberance tips rather than a continuous adhesive layer. This segmentation allows effective bonding with minimal adhesive material, reducing both material usage and application complexity.
3Reliability
If multiple plies are combined to achieve desired properties, then product performance is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
By creating distinct surface qualities (micro-embossed outer plies, smooth inner plies) and applying adhesive only at specific locations (embossed tips), the patent simplifies the lamination process control while maintaining product performance. The localized approach reduces variability and complexity compared to uniform bonding across all plies.
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 solution results in a product that is bulky, thick, and soft, with improved tactile impression and lower grammage, achieving similar properties to five-ply products with fewer plies, thus reducing paper fiber consumption and environmental impact while maintaining thickness during winding operations.
Implementation Method 1
the first and second outer plies include a micro-embossing pattern
Implementation Method 2
The first outer ply is bonded to the first inner ply and the second inner ply through at least some tips of protuberances associated to the décor embossing pattern
Data Source
AI summary
A multi-ply tissue paper product includes at least four plies made of tissue paper base-sheet or non-woven. Two inner plies are positioned between a first outer ply on one side and a second outer ply on another side. The two inner plies are flat plies. The first and second outer plies include a micro-embossing pattern. Only one of the outer plies further includes a décor embossing pattern. The multi-ply tissue paper product is configured to provide improved thickness and strength parameters with less use of paper fiber material.