Multi-Ply Tissue Embossing for Roll-Stable Bulk and Softness
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Solution Overview
Problem
Conventional embossed tissue products often exhibit non-uniformity in appearance when rolled, due to compression of embossments, which detracts from their aesthetic appeal and can result in suboptimal bulk and softness properties.
Innovation Solution
The development of multi-ply tissue products with embossments that have a height greater than 500 µm and a ratio of average width at 100% height to average width at 25% height greater than 3.0, combined with dome-like structures between embossments, to enhance pattern clarity and tissue properties such as bulk and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional embossing patterns are used, then tissue products can be manufactured with standard appearance, but the embossments become non-uniform and compressed when rolled, detracting from aesthetic appeal
Solution Approach 1:
The embossment design features an asymmetric cross-sectional profile with a narrow bottom portion and a wider top portion, creating a tapered shape that prevents uniform compression during rolling. This asymmetric geometry allows the embossments to maintain their visual appearance and structural integrity when the tissue is wound into rolls, resolving the contradiction between initial shape uniformity and rolled appearance stability
Solution Approach 2:
The invention specifies precise dimensional parameters for the embossments, including a height greater than 500 μm and a width ratio (W100/W25) greater than 3.0, which fundamentally changes the embossment geometry from conventional designs. These parameter changes create embossments with improved compressive resistance and aesthetic retention during the rolling process
2Volume of moving object
If embossment height is increased to improve softness and bulk, then tissue product softness and bulk are enhanced, but embossment clarity and definition may be compromised
Solution Approach 1:
The invention optimizes multiple geometric parameters simultaneously: embossment height (>500 μm), bottom width (narrow portion), top width, and the width ratio (W100/W25 > 3.0). This multi-parameter optimization achieves both high embossment clarity through the narrow base and enhanced bulk through the tall, voluminous structure, resolving the contradiction between clarity and bulk
3Quantity of substance
If multiple plies of lightweight material are used to reduce basis weight, then material efficiency is improved, but maintaining strength and structural integrity becomes more difficult
Solution Approach 1:
The embossments feature a dome-like curved structure with a rounded top portion, which distributes mechanical stresses more effectively than flat or sharp-edged embossments. This curvature in the embossment design contributes to enhanced structural integrity and tensile strength in multi-ply lightweight tissue products, resolving the contradiction between reduced basis weight and maintained strength
Data Source
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AI summary
Disclosed are multi-ply embossed tissue products having improved softness, strength, embossment clarity and/or embossment height compared to prior art embossed tissue products. The multi-ply tissue products may comprise an embossed tissue ply having a basis weight less than about 25 grams per square meter (gsm) and relatively deep embossments, such as an embossment height from about 500 to about 1,000 µm and relatively narrow bottom portions compared to top portions. The combination of these elements provides an aesthetically pleasing and well-defined embossment, while improving important tissue product properties such as sheet and roll bulk and softness.