Tissue Emboss Elements with Abatement for Bunching Reduction
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Solution Overview
Problem
Premium absorbent paper products face issues with bunching and wrinkling due to emboss patterns with continuous, high aspect ratio elements aligned in the machine direction, which limits pattern choices and affects product softness and strength.
Innovation Solution
Incorporating an abatement component, such as a tapered or multi-apex emboss element design, to absorb or dissipate web tension, reducing bunching and wrinkling without altering the emboss pattern's appearance or feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If continuous, high aspect ratio emboss elements aligned in the machine direction are used, then emboss definition and perceived softness are improved, but bunching and wrinkling occur
Solution Approach 1:
The emboss element is segmented into multiple apexes (e.g., dual-apex, triple-apex configurations) along its length. This segmentation allows the single emboss element to accommodate machine direction stretch through multiple contact points while maintaining continuous visual appearance, thereby preventing bunching and wrinkling while preserving emboss definition and perceived softness.
Solution Approach 2:
Different portions of the emboss element are designed with varying properties - the apexes provide localized contact points that manage stretch, while the continuous visual appearance maintains aesthetic quality. The emboss element has non-uniform structure with specific apex locations optimized to prevent bunching in critical areas while maintaining softness in others.
2Object-affected harmful factors
If smaller emboss elements are used to avoid bunching, then bunching and wrinkling are reduced, but pattern definition and visual appeal are compromised
Solution Approach 1:
Instead of using multiple small separate emboss elements, the invention uses a single continuous emboss element that is segmented into multiple apexes. This maintains the visual appearance of a large, well-defined pattern element while the multi-apex structure prevents bunching by distributing contact points along the element length.
Solution Approach 2:
The emboss element transitions from a simple linear feature to a three-dimensional structure with multiple apexes at different positions. This adds a vertical dimension (height variation) to the otherwise linear emboss element, allowing it to maintain visual definition while managing machine direction stretch through the apex configuration.
Data Source
AI summary
Products having reducing tissue wrinkling, puckering, and bunching and improved emboss definition, emboss visibility, and perceived softness are described. The methods comprise embossing the tissue sheet with a emboss elements having segments aligned in the machine direction and including an abatement component, such as a tapered width or a multi dual-apex, that can absorb machine direction stretch during the production of the product.