Web Substrate Emboss Design for Quilted Appearance and Bond Strength
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Solution Overview
Problem
Existing tissue paper products face challenges in maintaining a soft, quilted appearance and high bond strength while providing aesthetic appeal, as embossing processes like knob-to-knob embossing tend to lose thickness and nested embossing may not adequately support embossed patterns under pressure.
Innovation Solution
The development of a tissue paper product with an embossed surface featuring a ratio of line embossment area to dot embossment area greater than 1.5, utilizing a combination of regular and repeating, or irregular and asymmetric embossing patterns to enhance aesthetic appeal and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If knob-to-knob embossing is used to increase thickness and bulk, then the web substrate gains improved aesthetics and water holding capacity, but the pillow regions collapse under pressure during converting and packaging, losing the thickness benefit
Solution Approach 1:
The patent applies nested embossing where embossing elements of one roll mesh between the embossing elements of the opposing roll, creating interlocking patterns that provide structural support. The male pattern knobs nest within the female pattern recesses, preventing pillow collapse while maintaining thickness and bulk throughout the converting and packaging processes.
2Shape
If nested embossing is used to maintain quilted appearance and support patterns, then aesthetic appeal is improved, but the bond strength between plies may be insufficient without additional lamination mechanisms
Solution Approach 1:
The patent combines nested embossing with a lamination mechanism where embossed regions of plies are brought into contacting relationship. The interlocking nested patterns create mechanical interlocking between plies, and when combined with adhesive application in the nip region, this merging of embossing and lamination functions provides both the desired quilted appearance and sufficient bond strength.
3Stability of the object's composition
If multiple plies are embossed to create aesthetic patterns and joining, then the plies are maintained in face-to-face contacting relationship, but the complexity of the embossing process increases
Solution Approach 1:
The patent designs the nested embossing rolls to perform multiple functions simultaneously: creating aesthetic patterns, providing structural support to prevent collapse, and facilitating ply joining through interlocking contact regions. This multi-functionality reduces the need for separate processes while maintaining face-to-face contacting relationship between plies throughout converting and packaging.
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 tissue paper product that maintains a soft, quilted appearance and high bond strength, with improved consumer appeal through optimized embossment patterns that balance aesthetics and functionality.
Implementation Method 1
Embossing elements on the rolls compress and/or deform the web
Implementation Method 2
An adhesive is applied to the embossed regions of the web substrate to bond the plies together
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 at least about 0.2 percent line embossments and a ratio of line embossment area to dot embossment area greater than 1.5.