Multi-Ply Tissue Roll Structure Balancing Bulk and Firmness
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Solution Overview
Problem
Tissue manufacturers face challenges in producing rolled tissue products with high bulk and firmness while maintaining acceptable cost, as increasing basis weight typically compromises roll bulk, and consumers prefer large diameter rolls with good firmness, absorbency, and softness.
Innovation Solution
The development of a spirally wound multi-ply tissue web with specific properties, including Kershaw roll firmness, roll bulk, basis weight, and surface smoothness, achieved through optimized papermaking processes such as through-air drying and creping, which balances roll firmness and bulk without sacrificing sheet softness and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the basis weight of the tissue sheet is increased to provide greater absorbency and hand protection, then consumer preference for softness and absorbency is improved, but roll bulk decreases making it challenging to achieve high bulk
Solution Approach 1:
The patent changes the physical parameters of the tissue sheet by controlling basis weight within specific ranges (30-50 gsm) and engineering roll bulk (10-20 cc/g) to achieve optimal balance between absorbency and roll bulk, resolving the contradiction through precise parameter optimization
Solution Approach 2:
The patent employs multi-ply tissue structures combining different tissue layers with specific properties to achieve both high absorbency and maintained roll bulk, using composite construction to satisfy conflicting requirements
2Volume of stationary object
If the tissue roll is wound loosely to increase roll bulk, then roll bulk is improved, but firmness decreases making the roll easily deformed and unappealing to consumers
Solution Approach 1:
The patent optimizes the winding tension parameters to achieve a specific firmness range (5-10 mm Kershaw) while maintaining high roll bulk, using parameter control to resolve the contradiction between bulk and firmness
Solution Approach 2:
The patent employs dynamic winding processes that adjust tension and speed to create rolls with optimal bulk-to-firmness ratio, allowing the structure to achieve both high bulk and adequate firmness through controlled dynamic parameters
3Length of stationary object
If a large diameter roll is provided to convey sufficient material and value, then consumer perception of value is improved, but maintaining acceptable cost of manufacture becomes challenging
Solution Approach 1:
The patent optimizes basis weight and roll bulk parameters to achieve large diameter rolls with improved value perception while controlling material consumption and manufacturing cost through precise parameter management
Solution Approach 2:
The patent maintains uniform tissue properties throughout the roll structure to ensure consistent quality and value perception across the entire product, reducing waste and rework costs
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 approach results in tissue products with improved roll firmness, bulk, and surface properties, such as high geometric mean tensile strength and low shear hysteresis, maintaining sheet softness and strength across various basis weights, enhancing consumer preferences for absorbency and durability.
Implementation Method 1
through-air dried multi-ply tissue web
Implementation Method 2
spirally wound into a roll
Data Source
AI summary
Spirally wound paper products are disclosed having desirable roll bulk, firmness and softness properties. The rolled products can be made from a multiple ply tissue webs formed according to various processes. Tissue webs having basis weights greater than about 40 grams per square meter were wound into rolls having a Kershaw roll firmness of less than about 9 mm and a roll bulk of greater than about 15 cc/g. Similarly, tissue webs having basis weights less than about 40 grams per square meter were wound into rolls having a Kershaw roll firmness of less than about 9 mm and a roll bulk of greater than about 18 cc/g.