Multi-Ply Tissue Embossment and Bonding for Absorption
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Solution Overview
Problem
Existing tissue paper products face challenges in achieving optimal thickness, strength, softness, bulkiness, and absorption capacity, particularly in multi-ply configurations.
Innovation Solution
A tissue paper product comprising at least three plies, where the top and bottom plies are embossed with different embossment heights and the inner ply is not pre-embossed, bonded using adhesive and/or mechanical methods, with at least one embossing roll heated to enhance shape memory and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple plies are combined with adhesive bonding to increase thickness and absorption, then the product bulk and absorption capacity improve, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple bonding methods (adhesive bonding and mechanical embossing bonding) to join plies together. This merging of bonding mechanisms allows the product to achieve both high absorption capacity through multiple plies and controlled manufacturing complexity by using established bonding technologies in combination.
Solution Approach 2:
The patent uses composite material structures by combining different ply configurations with varying embossment patterns and bonding methods. This creates a multi-layer composite structure that optimizes both absorption performance and manufacturing feasibility through the synergistic combination of different material layers and bonding techniques.
2Volume of moving object
If embossment height is increased to improve thickness and bulk, then the product thickness and bulkiness improve, but the tensile strength decreases
Solution Approach 1:
The patent applies different embossment heights at different locations on the same ply. Higher embossments are created in specific regions to increase bulkiness and thickness where needed, while lower embossments are maintained in other regions to preserve tensile strength. This local variation in embossment quality allows simultaneous optimization of both bulkiness and strength.
3Strength
If adhesive bonding is used to combine plies to improve strength, then the ply bonding strength improves, but the cost and manufacturing complexity increase
Solution Approach 1:
The patent uses adhesive as an intermediary substance to bond plies together. The adhesive layer acts as a mediator that creates strong bonding between plies while allowing for controlled application and curing processes. This intermediary approach enables strong ply bonding without requiring complex mechanical bonding systems, thus improving ease of manufacture while maintaining high bonding strength.
4Stability of the object's composition
If heated embossing roll is used to enhance shape memory, then the embossment shape retention when wet improves, but the energy consumption increases
Solution Approach 1:
The patent utilizes phase transition of the adhesive material during heated embossing. The adhesive is heated to a temperature where it transitions to a more fluid state, allowing it to flow and conform to the embossment pattern, then cools and solidifies to lock in the shape. This phase transition mechanism enables enhanced shape memory retention when wet while controlling energy consumption through targeted heating only during the embossing process.
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 results in a product with improved thickness, tensile strength, and absorption capacity, maintaining embossment shape even when wet, while maintaining cost-effectiveness and suitable for various applications like toilet paper and household towels.
Implementation Method 1
with at least one embossing roll heated to enhance shape memory and resilience
Implementation Method 2
bonded using adhesive and/or mechanical methods
Data Source
AI summary
Disclosed is a tissue paper product including at least three plies with a top ply and bottom ply as outermost plies, and an inner ply between the top and bottom plies, a basis weight of the tissue paper product being 30-150. The top ply being embossed with at least two types of embossments including first embossments with a first height and second embossments with a second height, the first height being larger than the second height, and the bottom ply is embossed, the inner ply and the top ply being bonded with the bottom ply at tips of the first embossments with an adhesive, such as a lamination glue, or the inner ply, the top ply, and the bottom ply are ply-bonded with mechanical bonding, at least one of the top ply and the bottom ply being embossed by a heated embossing roll.