Multi-Ply Tissue Paper with Edge Embossing to Reduce Fiber Dust
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Solution Overview
Problem
Multi-ply tissue paper products generate loose fibers during use, leading to discomfort and inhomogeneities, and existing manufacturing processes struggle to maintain high caliper, softness, bulkiness, absorption capacity, and strength while avoiding fiber migration and dust generation.
Innovation Solution
A multi-ply tissue paper product design featuring a high caliper inner layer with loose cellulosic fibers positioned between outer plies, utilizing a dense association zone at the edge and a less dense zone at the central usage area, with embossing patterns to trap and stabilize fibers, and a manufacturing method that includes spraying an adhesive and embossing to secure the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multi-ply tissue paper products are made with loose cellulosic fibers between outer plies to increase bulk and softness, then product softness and bulkiness are improved, but loose fibers migrate and generate dust during use
Solution Approach 1:
An adhesive layer is introduced as an intermediary substance between the loose cellulosic fibers and the outer plies. This adhesive mediator secures the loose fibers in place, preventing their migration and dust generation while preserving the bulk and softness benefits that loose fibers provide to the tissue product.
Solution Approach 2:
The adhesive application parameters are optimized to achieve the right balance - applying sufficient adhesive to secure fibers but not so much that it compromises softness. The adhesive is applied in specific patterns (dots or lines) rather than uniformly, changing the distribution parameter to maintain bulk while preventing fiber migration.
2Stability of the object's composition
If adhesive is applied to secure loose fibers between plies, then fiber migration is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The adhesive application is segmented into discrete locations (dots or lines) rather than continuous coverage. This segmentation reduces the total amount of adhesive needed and simplifies the application process, lowering manufacturing complexity while still providing sufficient fiber stabilization at critical locations.
Solution Approach 2:
Instead of applying adhesive uniformly across the entire surface, the solution uses partial action by applying adhesive only at specific strategic locations where fiber migration is most likely to occur. This partial application reduces complexity and material usage while achieving the necessary stabilization effect.
3Shape
If high caliper inner layer with loose fibers is used to maintain softness and absorbency, then product softness and absorption capacity are improved, but delamination force decreases making tearing easier
Solution Approach 1:
The adhesive parameters (application pattern, quantity, and distribution) are optimized to achieve the right balance between bonding strength and tissue softness. By using discrete adhesive applications rather than uniform coverage, the product maintains adequate delamination resistance while preserving the soft, loose fiber structure that provides absorbency and comfort.
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 effectively reduces fiber dust and migration, maintains product softness and absorbency, and ensures high delamination force for easy tearing, while being environmentally flushable and compatible with high-speed manufacturing processes.
Implementation Method 1
spraying an adhesive and embossing to secure the layers
Implementation Method 2
embossing the first association zone at a peripheral area of the multi-ply tissue paper product according to a first pattern of association elements... embossing the second association zone at a central usage area
Data Source
Figure 1A~2
Figure 3~4
Figure 5
AI summary
A multi-ply tissue paper product (1) comprising at least two plies made of tissue paper base-sheet, comprises: - a high caliper ranging from about 0.5 to about 1.5 mm, high bulk ranging from about 25 to about 75 cm3/g absorbent inner layer(4)including loose cellulosic fibers positioned between a first outer ply(2) on one side and a second outer ply (3) on another side; - a first association zone (5) and a second zone (6) where the inner layer (4), the first outer ply (2) and the second outer ply (3) are associated together. The first association zone (5) is positioned at an edge (9A) of the multi-ply tissue paper product (1) according to a first pattern of association elements (7) having a high elements density corresponding to a surface association of at least about 6%, in particular at least about 8%, especially at least about 10% of a total surface of the multi-ply tissue paper product arranged to close the edge (9A) of the multi-ply tissue paper product with respect to the loose cellulosic fibers. The second zone (6) is positioned at a central usage area of the multi-ply tissue paper product (1). The first pattern of association elements comprises at least two parallel lines of association elements with a first distance (d1) between two adjacent lines less than half square root of three of a mean fluff fiber length (lm) and a second distance (d2) between adjacent association elements in a line less than themean fluff fiber length (lm).