Through-Air Drying Fabric with 3D Pattern for High-Bulk Smooth Towel
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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 one or more of 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, by structuring the tissue web with elevations and landing areas on the fabric surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the basis weight of the tissue sheet is increased, then the tissue product is perceived as 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 patterned surface on the tissue product by embossing or molding during the papermaking process. This adds vertical dimensionality to the tissue structure, creating peaks and valleys that increase perceived bulk and softness without requiring increased basis weight. The 3D surface structure allows the tissue to maintain high roll bulk while using lighter weight materials.
2Volume of stationary object
If the tissue roll is wound loosely to increase roll bulk, then large diameter and high bulk are achieved, but firmness is reduced and the roll becomes easily deformed
Solution Approach 1:
The patent applies local quality by creating regions of varying density and structure within the tissue roll. The three-dimensional patterned surface creates localized areas of increased bulk and softness while maintaining overall roll integrity. This allows the roll to be wound more loosely for high bulk while the structured tissue maintains sufficient firmness to resist deformation.
3Manufacturing precision
If the surface topography is altered to improve perceived smoothness, then consumer appeal is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates the three-dimensional surface pattern directly into the papermaking process itself, rather than applying it as a post-manufacturing treatment. The molded or embossed pattern is formed on the tissue web while it is still in the forming section of the paper machine, integrating the surface finishing operation into the base manufacturing process and avoiding additional complex equipment.
Data Source
AI summary
The inventive tissue products have high bulk and improved surface smoothness, particularly compared to tissue products of similar basis weights. The tissue products may have a sheet bulk greater than about 15 cc/g, such as from about 15 to about 25 cc/g and a surface smoothness S90 value less than about 90 μm. Further, the tissue products are generally strong enough to withstand use and may have a geometric mean tensile strength greater than about 2,000 g/3″. The tissue products may be converted into rolled tissue products having improved roll bulk, such as a roll bulk greater than 15 cc/g.