Tessellating Paper Structure for Strength and Absorbency
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Solution Overview
Problem
Conventional papermaking processes struggle to produce paper products with high strength and absorbency while maintaining a non-embossed pattern and reduced thickness, as they often compromise on either strength or absorbency due to the limitations of fiber orientation and drying methods.
Innovation Solution
A paper product with a pattern of tessellating unit cells, featuring densified and undensified fiber structures, is created using a foraminous imprinting member with deflection conduits, allowing for increased fiber orientation and fluid communication, resulting in a high-density network with dispersed low-density domes, enhancing both strength and absorbency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional papermaking processes use traditional drying and pressing methods, then the paper web achieves sufficient strength, but the absorbency and softness are compromised due to excessive compaction and loss of fiber orientation
Solution Approach 1:
The paper web is segmented into multiple plies with distinct functions: a high-density strength-providing ply and a low-density absorbency-providing ply. This segmentation allows each layer to optimize its specific function without compromising the other, resolving the contradiction between strength and absorbency
Solution Approach 2:
Different regions of the paper product are given different densities and properties. The first ply has high density and strength for structural integrity, while the second ply has low density and high absorbency for fluid uptake. This local differentiation allows the product to simultaneously achieve both strength and absorbency
2Strength
If the paper web is compacted to increase density and strength, then the tensile strength improves, but the thickness is reduced and absorbency is compromised
Solution Approach 1:
The paper product is divided into multiple plies with different compaction levels. The first ply is highly compacted for strength, while the second ply remains less compacted to maintain thickness and absorbency. This segmentation resolves the contradiction between strength and thickness
3Ease of manufacture
If fibers are oriented predominantly in the X-Y plane during web formation, then the web formation is simplified, but the Z-direction structural rigidity and resistance to mechanical pressure are minimized
Solution Approach 1:
Different regions of the paper web are given different fiber orientations. The first ply has fibers oriented to provide strength in the plane of the web, while the second ply has fibers oriented to provide thickness and Z-direction rigidity. This local differentiation resolves the contradiction between ease of manufacture and structural rigidity
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 achieves a significant increase in tensile strength and absorbency, along with a decrease in residual water content, compared to commercial products, while maintaining a macroscopically mono-planar structure and reduced thickness.
Implementation Method 1
a foraminous imprinting member with deflection conduits, allowing for increased fiber orientation and fluid communication
Implementation Method 2
Each pillow area comprises an un-densified fiber structure and each of the land areas being comprises a densified fiber structure
Data Source
AI summary
A paper product having a plurality of tessellating unit cells forming a pattern is disclosed. Each unit cell has a center and at least two continuous land areas extending in at least two directions from the center and a plurality of pillow areas each surrounded by at least one of the continuous land areas. Each of the continuous land areas at least bifurcates to form a continuous land area portion having a first width before bifurcation and at least two continuous land area portions having a second width after bifurcation. The first width is greater than the second width. Each of the continuous land area portions having the first width has a first number density and each of the at least two continuous land area portions having the second width has a second number density. The first number density is less than the second number density.