Tissue paper products, rolls and stacks of tissue paper products, and manufacturing methods
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tissue paper products face challenges in achieving optimal thickness, strength, softness, bulkiness, and absorption capacity, particularly when manufactured with multiple plies.
Innovation Solution
A tissue paper product comprising between two and four plies, where at least the first ply is a structured paper ply embossed with a heated embossing roll, enhancing its shape memory and resilience, and optionally combined with a second ply made of Conventional Wet Press paper, using adhesive or mechanical bonding for ply-bonding, to achieve higher thickness and absorption while maintaining tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple plies are combined using adhesive bonding or mechanical bonding, then the tissue paper product achieves sufficient strength and structure, but the thickness and absorption capacity are limited
Solution Approach 1:
The patent applies embossing to create three-dimensional structures on the tissue paper surface, transforming a two-dimensional flat sheet into a three-dimensional textured structure. This dimensional change increases the effective thickness and volume of the tissue paper without adding more plies, thereby improving absorption capacity while maintaining tensile strength through the bonded ply structure.
Solution Approach 2:
The embossing process creates porous structures and air pockets within the tissue paper plies. These porous regions increase the internal volume available for fluid absorption while maintaining the structural integrity and strength of the bonded plies. The controlled porosity enhances absorption capacity without compromising the tensile strength achieved through adhesive or mechanical bonding.
2Quantity of substance
If the tissue paper product is made thicker with more plies, then the absorption capacity increases, but the manufacturing cost increases
Solution Approach 1:
Instead of increasing the number of plies to enhance absorption capacity, the patent employs embossing to create three-dimensional structures within existing plies. This approach increases the effective volume and absorption capacity without the additional material and manufacturing costs associated with producing and bonding extra plies.
Solution Approach 2:
The embossing process modifies the physical parameters of the tissue paper by creating surface textures and internal voids. This parameter change increases the absorption capacity through enhanced surface area and internal volume, providing a cost-effective alternative to simply adding more plies to the product.
3Shape
If conventional embossing is used, then the tissue paper gains surface texture, but the shape memory and resilience are insufficient
Solution Approach 1:
The patent utilizes heat embossing, which involves thermal energy to modify the tissue paper structure. The heat application causes phase transitions in the cellulose fibers, enabling them to set into the desired embossed shape with improved shape memory. This thermal processing enhances the resilience and stability of the embossed features compared to conventional cold embossing methods.
Solution Approach 2:
By applying thermal energy during the embossing process, the patent changes the physical state and properties of the tissue paper material. This parameter change (temperature) enables the fibers to better retain the embossed shape and improves shape memory, while the subsequent cooling sets the new configuration with enhanced stability and resilience.
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 results in tissue paper products with increased thickness and absorption capacity while maintaining or improving tensile strength, and can be manufactured at a lower cost compared to products without heat-embossed plies, with the embossing process allowing for adjustable properties like higher tensile strength or larger thickness.
Implementation Method 1
the first ply has been embossed with a heated embossing roll
Data Source
AI summary
Disclosed is a tissue paper product, including between two and four plies, including at least a first ply and a second ply, the two plies, three plies, or four plies being ply-bonded, to form the tissue paper product, the first ply and the second ply being the outermost plies of the tissue paper product, a grammage of the tissue paper product being in a range of 24 to 50 g/m2 if a total number of plies of the tissue paper product is 2, in a range of 34 to 65 g/m2 if a total number of plies of the tissue paper product is 3, and in a range of 55 to 95 g/m2 if a total number of plies of the tissue paper product is 4, the first ply being a structured paper ply.