Tissue Web Emboss Pattern for Thickness and Softness Retention
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Solution Overview
Problem
Existing tissue paper products face challenges in maintaining a soft, quilted appearance and high caliper during converting and packaging processes, as embossing patterns tend to collapse under pressure, and there is a need for aesthetically pleasing decorative patterns without compromising softness, absorbency, and bond strength.
Innovation Solution
The development of a tissue paper product with specific embossing patterns, comprising 0.0 to 1.2 percent dot embossments and 10.0 to 20.0 percent line embossments, which are strategically designed to enhance aesthetics and functional properties, such as thickness and strength, while optimizing bond strength and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional embossing patterns are used to enhance aesthetic appeal and thickness, then the visual appeal and bulk are improved, but the embossed regions collapse under pressure during converting and packaging, losing thickness and aesthetic quality
Solution Approach 1:
The embossed pattern is segmented into discrete regions (embossed sites) distributed across the ply rather than continuous compression. This segmentation allows the embossed regions to maintain structural integrity and resist collapse under pressure, while still providing the desired aesthetic appearance and thickness enhancement.
Solution Approach 2:
The embossing process creates preliminary compressed regions that serve as bonding sites before the final product assembly. These pre-compressed regions maintain their shape and provide stable bonding points throughout converting and packaging operations, preventing later collapse.
2Strength
If embossing compression is applied to join plies and create aesthetic patterns, then bond strength and visual appeal are improved, but the softness and drape of the tissue product deteriorate
Solution Approach 1:
Compression is applied locally at discrete embossed sites rather than uniformly across the entire ply. This localized compression creates strong bonds at specific points while leaving the majority of the tissue structure uncompressed, thereby preserving overall softness and drape properties.
Solution Approach 2:
Only a small portion of the ply surface (about 1% or less) is subjected to compression at embossed sites. This partial action provides sufficient bond strength through concentrated compression points while minimizing the impact on overall tissue softness and flexibility.
3Volume of moving object
If heavy embossing is used to increase bulk and aesthetic appeal, then thickness and visual quality are improved, but absorbency and softness are compromised
Solution Approach 1:
The bulk enhancement is achieved through segmented embossed sites rather than continuous compression. This segmentation maintains the porous structure and compressibility of the tissue between embossed regions, preserving absorbency while providing the desired thickness and aesthetic appearance.
Data Source
AI summary
A web substrate having at least one embossed ply having a surface thereof is disclosed. The surface has surface area comprising from 0.0 percent to about 1.2 percent dot embossments and from about 10.0 percent to about 20.0 percent line embossments.