Paper tissue with high bulk and low lint
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Solution Overview
Problem
Wood pulp fibers used in personal care products face challenges in achieving a balance between sheet integrity, bulk, and low lint content due to their short fiber length and processing methods, which often result in compromised properties like softness and biodegradability when binder fibers are added to improve integrity.
Innovation Solution
A tissue paper product with an ultra-low density ply composed of greater than 50% cellulosic fibers, bonded by hydrogen bonding, and incorporating a foaming surfactant to create a highly porous, open-celled structure with minimal binder content, achieving a density less than 0.04 g/cc and low lint values while maintaining wet tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If air laying process is used to achieve high bulk and open fiber structure, then bulk is improved, but sheet integrity and lint control deteriorate
Solution Approach 1:
A hydrophobic binder fiber acts as an intermediary between hydrophilic wood pulp fibers, creating water-resistant bonds that maintain sheet integrity while preserving the air-laid high-bulk structure. The binder fiber mediates the bonding process without requiring extensive hydrogen bonding that would compact the fiber structure.
Solution Approach 2:
The invention changes the bonding mechanism parameter from relying solely on hydrogen bonding (which causes compaction) to using hydrophobic interactions and mechanical interlocking via binder fibers, enabling high bulk to be maintained while achieving adequate sheet integrity.
2Reliability
If binder fibers or adhesive are added to improve sheet integrity and reduce lint, then sheet integrity is improved, but softness and biodegradability deteriorate
Solution Approach 1:
The binder fiber is applied locally at bonding points between wood pulp fibers rather than uniformly throughout the sheet, providing structural reinforcement only where needed for integrity while leaving the majority of the sheet structure soft and biodegradable.
Solution Approach 2:
The invention uses natural, biodegradable binder fibers (such as lignin or natural fiber binders) that are inexpensive and environmentally friendly, replacing synthetic adhesives while maintaining sheet integrity and preserving biodegradability.
3Object-generated harmful factors
If wet laying process is used to achieve low lint through extensive hydrogen bonding, then lint control is improved, but bulk and wet integrity deteriorate
Solution Approach 1:
The hydrophobic binder fiber serves as a mediator that enables lint control through mechanical interlocking and water-resistant bonding without requiring the extensive hydrogen bonding network that causes fiber mat compaction and bulk loss in traditional wet-laid processes.
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 provides a tissue paper product with high bulk, low lint content, and improved sheet integrity, maintaining desired properties like softness and biodegradability, while achieving a Gelbo Lint Value less than 5 and a wet tensile strength of at least 10 g-f.
Implementation Method 1
the cellulosic fiber... are bonded to one another by hydrogen bonding
Implementation Method 2
incorporating a foaming surfactant to create a highly porous, open-celled structure
Data Source
AI summary
A tissue paper product is provided having at least one ultra-low density ply having a highly porous, open-celled structure and that comprises cellulosic fibers, a water insoluble binder and a foaming surfactant. The cellulosic fiber comprises greater than 50% by weight of the ply and are bonded to one another by hydrogen bonding. Further, the ply has a density less than about 0.04 g/cc and yet still provides low lint and high strength properties with the use of minimal binder. The ultra-low density ply may comprise or be included in sheets forming a stack of dispensable wipers or may be employed as or part of an absorbent core or liquid distribution layer of a personal care absorbent personal care product such as a diaper or feminine pad.