Pulp Fibrous Sheet Compression for Softness and Strength
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Solution Overview
Problem
Existing pulp fibrous accumulated sheets require a papermaking step and often result in a multi-ply body with reduced softness and inappropriate strength.
Innovation Solution
A pulp fibrous accumulated sheet is produced without papermaking, featuring a liquid permeable layer with crushed pulp fibers and a binder, along with fiber crimped parts formed by compression and pressurization, ensuring the fibers straddle adjacent crimped parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a papermaking step is used to produce the pulp fibrous accumulated sheet, then the sheet can be formed with sufficient strength, but the production process becomes more complex and the sheet forms a multi-ply body that reduces softness
Solution Approach 1:
The invention extracts and eliminates the papermaking step from the production process. Instead of using traditional papermaking methods that create multi-ply structures, the patent directly forms the pulp fibrous accumulated sheet through a simplified process that combines fiber accumulation, compression, and binder application in a single integrated operation, thereby reducing production complexity while maintaining sheet strength
Solution Approach 2:
The invention merges multiple production steps into a single integrated process. The fiber accumulation, compression/pressurization, and binder application are combined into one continuous operation, eliminating the need for separate papermaking steps and reducing overall production process complexity while still achieving the desired sheet strength
2Strength
If a papermaking step is used to produce the pulp fibrous accumulated sheet, then the sheet can be formed with sufficient strength, but the sheet forms a multi-ply body that reduces softness
Solution Approach 1:
The invention extracts the papermaking step that causes multi-ply formation, directly producing a single-layer pulp fibrous accumulated sheet. This elimination of the papermaking process prevents the formation of multiple plies, thereby maintaining the softness of the sheet while still achieving sufficient strength through the optimized compression and binder application
Solution Approach 2:
The invention applies local quality by creating fiber crimped parts with specific structural characteristics. The compression and pressurization steps create localized crimped regions that provide strength without requiring a multi-ply structure, allowing the sheet to maintain both adequate strength and high softness through localized structural optimization rather than overall multi-ply construction
3Shape
If fiber crimped parts are formed by compression and pressurization, then the sheet maintains its shape without papermaking, but the production process requires additional compression equipment
Solution Approach 1:
The invention merges the compression and pressurization functions into a single integrated step that is part of the overall fiber accumulation process. The compression equipment used creates fiber crimped parts while simultaneously consolidating the sheet structure, eliminating the need for separate shaping equipment and reducing overall device complexity despite adding compression capability
Solution Approach 2:
The compression and pressurization step serves multiple functions: it forms the fiber crimped parts for shape stability, consolidates the fiber structure, and prepares the sheet for binder application. This multi-functional approach reduces the need for additional specialized equipment, as the compression step performs multiple roles in the production process
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 resulting sheet maintains its shape without forming a multi-ply body, achieving appropriate strength and improved softness, while also being water-disintegrable or non-water-disintegrable depending on the binder used.
Implementation Method 1
a liquid permeable pulp fibrous accumulated layer containing a crushed pulp or base-fibers mainly including a crushed pulp, and a binder
Implementation Method 2
a plurality of fiber crimped parts formed by compression and pressurization
Implementation Method 3
a fiber accumulating step of forming a fibrous accumulated body on a mesh body by subjecting a crushed pulp or base-fibers mainly including a crushed pulp to fiber accumulation by aspiration
Implementation Method 4
a drying step of drying the fibrous accumulated body after the binder application step to form a liquid permeable pulp fibrous accumulated layer
Data Source
AI summary
Provided is a pulp fibrous accumulated sheet including: a liquid permeable pulp fibrous accumulated layer containing a crushed pulp or base-fibers mainly including a crushed pulp, and a binder, and a plurality of fiber crimped parts formed by compression and pressurization, the fiber crimped parts being formed so that crushed pulp fibers each straddling the adjacent fiber crimped parts are present.