Single-Ply Tissue Roll Bulk and Firmness Through-Air Drying
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Solution Overview
Problem
Manufacturers face challenges in producing rolled tissue products with high bulk and firmness while maintaining acceptable cost, as increasing basis weight reduces roll bulk and achieving high roll bulk compromises sheet stiffness and absorbency.
Innovation Solution
The use of high topography fabrics in both transfer and through-air drying positions during the through-air drying process for single-ply tissue webs, resulting in improved bulk, reduced stiffness, and enhanced roll firmness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the basis weight of tissue sheets is increased to provide greater absorbency and hand protection, then sheet quality improves, but achieving high roll bulk becomes more challenging since increasing basis weight reduces the number of wraps at the same roll weight
Solution Approach 1:
The patent changes the physical parameters of the tissue sheet by controlling basis weight, caliper, and bulk characteristics through the papermaking process to achieve sheets that provide sufficient quality while maintaining roll bulk through optimized material properties rather than simply increasing thickness or weight
Solution Approach 2:
The patent applies different properties to different aspects of the tissue product - the sheet itself has sufficient basis weight for absorbency, while the roll structure achieves high bulk through optimized winding and sheet characteristics, allowing each component to fulfill its specific function without compromising the other
2Volume of stationary object
If tissue rolls are wound loosely to increase roll bulk, then bulk increases, but firmness decreases making rolls easily deformed and unappealing to consumers
Solution Approach 1:
The patent optimizes multiple parameters including sheet bulk, basis weight, and caliper to achieve a balance where the roll maintains high bulk while the sheet properties provide sufficient structural integrity and firmness when wound
Solution Approach 2:
The patent prepares the tissue sheet with specific bulk and strength characteristics before winding, ensuring that the sheet is pre-conditioned to maintain roll firmness while achieving high bulk through the winding process
3Ease of manufacture
If singly-ply tissue webs are produced to reduce cost, then manufacturing cost decreases, but softness and absorbency characteristics are reduced compared to multi-ply webs
Solution Approach 1:
The patent changes the physical and chemical parameters of single-ply tissue during the papermaking process, including fiber composition, basis weight, and bulk characteristics, to achieve softness and absorbency levels comparable to multi-ply products while maintaining the cost advantages of single-ply construction
Solution Approach 2:
The patent uses composite fiber materials and formulations in the single-ply web to achieve multi-ply-like performance characteristics, combining different fiber types and properties to create a single layer that provides both cost efficiency and superior softness and absorbency
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
This approach allows for the production of spirally wound tissue rolls with increased bulk and firmness, maintaining sheet softness and strength, thereby addressing the contradictory parameters of bulk, firmness, and cost effectively.
Implementation Method 1
forming a through-air-dried tissue using high topography fabrics in both the transfer and through-air drying positions
Data Source
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AI summary
Spirally wound paper products are disclosed having desirable roll bulk, firmness and softness properties. The rolled products can be made from single ply tissue webs formed according to various processes.