Selective Lotion Application for Tear-Resistant Toilet Paper Embossing
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Solution Overview
Problem
Conventional toilet paper embossed and impregnated with aqueous lotion chemicals faces issues of tearing due to reduced fiber strength, which affects its wiping and cleaning performance, especially for individuals with hemorrhoids or those using shower toilets, and lacks water disintegration properties suitable for modern toilet systems.
Innovation Solution
A method involving the selective application of aqueous lotion chemicals onto band-like continuous crepe paper using a printer, followed by embossing with an embossing roll that only contacts non-chemicals-application portions, ensuring the chemicals do not weaken the embossing areas, thereby maintaining strength and preventing tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aqueous lotion chemicals are applied to the entire surface of the base paper and embossing is performed, then the wiping property, bulkiness, moisture-retaining property, softness, and surface lubricating property are improved, but the tensile strength is reduced and paper breakage occurs during embossing
Solution Approach 1:
The patent applies aqueous lotion chemicals selectively to specific regions of the base paper rather than the entire surface. The chemical application portions are positioned to avoid the embossing convex portions, creating local quality differences where some areas have chemical impregnation (for softness and lubrication) while others maintain full fiber strength (for embossing integrity). This resolves the contradiction by allowing functional improvement in treated areas without compromising structural strength in untreated areas.
2Reliability
If the amount of applied aqueous lotion chemicals is increased or the depth of embossed concave portions is enlarged to improve wiping and bulkiness properties, then these functional characteristics are enhanced, but paper breakage is caused due to degraded strength
Solution Approach 1:
The patent creates local quality differentiation by restricting chemical application to specific zones that do not overlap with embossing convex portions. This allows the concave portions to achieve greater depth for improved bulkiness and wiping performance while the convex portions (which bear the embossing load) remain chemically untreated and maintain full fiber strength, preventing paper breakage even with deeper embossing.
3Reliability
If embossing convex portions are pressed against the base paper to create embossed concave portions, then the wiping property and bulkiness are improved, but the side wall of each embossed concave portion becomes elongated and tensile strength is reduced
Solution Approach 1:
The patent applies local quality control by positioning chemical application portions away from the embossing convex portions. This ensures that the side walls of embossed concave portions, which are subjected to tensile stress during use, remain free of chemical impregnation and maintain high fiber strength. The chemical treatment is concentrated in areas that do not require high mechanical strength, resolving the contradiction between wiping performance and side wall integrity.
4Reliability
If conventional embossing and chemical impregnation methods are used, then the functional characteristics are improved, but the toilet paper tears easily during pressing cleaning operations for patients with hemorrhoid disease or users of shower toilets
Solution Approach 1:
The patent implements local quality differentiation by strategically positioning chemical application portions to avoid areas that will form the side walls of embossed concave portions. This creates a structure where the surface lubricating function is provided by chemically treated areas, while the structural integrity and tear resistance are maintained in chemically untreated areas that form the load-bearing side walls. This resolves the contradiction by separating functional and structural roles across different spatial zones.
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
This approach enhances the wiping, bulkiness, moisture-retaining, and surface lubricating properties while ensuring the toilet paper's strength and water disintegration properties, reducing the frequency of tearing and improving overall performance for both users with hemorrhoids and those using shower toilets.
Implementation Method 1
a chemicals applying step of printing and applying aqueous lotion chemicals onto band-like continuous crepe paper by a printer
Implementation Method 2
an embossing step of passing the continuous crepe paper, which has been applied with the chemicals in the chemicals applying step, between an embossing roll with embossing convex portions and a backing roll making a pair with the embossing roll, while the embossing convex portions are brought into press-contact only to the non-chemicals-application portions
Implementation Method 3
the toilet paper needs to have high water absorption ability and to effectively conduct the cleaning operation by the above mentioned pressing manner, while it is in a water-absorbing state
Data Source
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Figure 3(A)~3(D)
AI summary
To solve problems such as tearing in using or manufacturing sanitary thin paper for household use that is embossed and applied with aqueous chemicals. The problem is solved by a method for manufacturing toilet paper, comprising: a chemicals applying step of printing and applying aqueous lotion chemicals onto band-like continuous crepe paper by a printer, while a pattern with a non-chemicals-application portions and chemicals-application portions is formed; and an embossing step where the embossing convex portions are brought into press-contact only to the non-chemicals-application portions of the continuous crepe paper so that the continuous crepe paper is embossed.