3D Textured Tissue Structure for Bulk and Smoothness Balance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Tissue manufacturers face challenges in producing rolled tissue products with high bulk, firmness, and surface smoothness while maintaining acceptable cost and quality, as increasing basis weight often compromises these properties.
Innovation Solution
The use of a through-air drying fabric with a three-dimensional design element during the papermaking process, which enhances sheet bulk and surface smoothness while maintaining roll firmness and tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the basis weight of tissue sheets is increased, then the tissue product is perceived as being softer and higher quality, but achieving high roll bulk becomes more challenging and bulk is decreased
Solution Approach 1:
The patent introduces a three-dimensional textured surface structure on the tissue product by forming raised patterns during the papermaking process. This dimensional change allows the tissue to achieve high basis weight while maintaining perceived softness and preventing the tissue from appearing flat or bulky in a negative sense, thereby resolving the contradiction between increased basis weight and maintained roll bulk
2Volume of stationary object
If the tissue roll is wound loosely to increase roll bulk, then the roll bulk increases, but the firmness decreases and the roll becomes easily deformed
Solution Approach 1:
The patent changes the surface topology parameter of the tissue from flat to three-dimensional textured. This parameter change allows the tissue to maintain structural integrity and firmness even when wound loosely, as the textured surface provides mechanical stability while preserving roll bulk. The three-dimensional structure prevents excessive deformation while maintaining the desired bulk characteristics
3Shape
If the surface topography is altered to improve perceived smoothness, then the tissue is perceived as softer, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by forming the three-dimensional textured surface during the papermaking process itself, rather than as a subsequent finishing step. The texture is created while the tissue is still in web form on the paper machine, using molded paper pulp or textured forming techniques. This preliminary formation integrates the surface structuring into the base manufacturing process, avoiding the need for separate post-production texturing equipment and reducing overall manufacturing complexity
Data Source
AI summary
The present disclosure provides high bulk tissue products, as well as an apparatus and methods for manufacturing the same. The tissue products provided herein not only have high bulk, but they also have improved surface smoothness, particularly compared to tissue products of similar basis weights.