Split Single-Ply Tissue Web for Multi-Ply Product Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing multi-ply tissue products require manufacturing individual basesheets for each ply, which is costly and inefficient.
Innovation Solution
A method involving the creation of a single ply tissue web with a layered structure, allowing it to be split into two separate webs, which are then combined to form a multi-ply tissue product, thereby eliminating the need for separate basesheet production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If individual basesheets are manufactured for each ply and then combined, then the multi-ply tissue product achieves desired caliper, softness, bulkiness, absorption capacity and strength, but the manufacturing process becomes costly and inefficient
Solution Approach 1:
The invention merges multiple ply manufacturing operations into a single basesheet production process. A multi-layered tissue web is formed with alternating layers of different fiber types, then split into separate plies that are combined to form the final multi-ply product. This eliminates the need to manufacture and handle multiple separate basesheets, thereby increasing productivity while the layered structure design ensures each ply maintains its required properties.
Solution Approach 2:
The invention segments the multi-layered tissue web into individual plies through a splitting process. The web is constructed with alternating layers (first fiber type, second fiber type, first fiber type) that can be divided to create separate plies with specific fiber compositions. This segmentation allows each ply to be tailored with appropriate fiber types while producing them from a single integrated web structure.
2Ease of manufacture
If multiple separate basesheets are produced and combined, then the final product achieves desired properties, but material and processing costs increase
Solution Approach 1:
The invention combines multiple fiber types into a single multi-layered web structure during one manufacturing cycle. Instead of producing separate basesheets from different fiber furnishes and then combining them, the alternating layer structure allows all fiber materials to be processed simultaneously in one line, reducing material handling, adhesive application, and energy costs while maintaining the ability to deliver different fiber types to different plies.
3Productivity
If a single ply basesheet is split into multiple webs, then productivity increases and costs reduce, but the basesheet structure must be specially designed to enable splitting
Solution Approach 1:
The invention applies local quality by creating alternating layers of different fiber types within the single basesheet. The first and third layers use a first fiber type while the second layer uses a second fiber type, creating zones with different properties. This local differentiation enables the web to be split into plies with specific fiber compositions, and the varying fiber types can provide different bonding characteristics that facilitate controlled splitting at designated interfaces.
Data Source
AI summary
In general, the present invention is directed to a process for producing multi-ply tissue products from a single ply tissue web and the resulting multi-ply products, which have good softness and strength characteristics. The process of the present invention generally involves producing a first single ply tissue web and then splitting the web into two separate single ply tissue webs that can be converted into a multi-ply web. In certain preferred embodiments the single ply web may be manufactured such that when it is split into two separate webs the two webs are substantially identical.