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. 2022 Jun 18;14(12):2485.
doi: 10.3390/polym14122485.

FEM Analysis Validation of Rubber Hardness Impact on Mechanical and Softness Properties of Embossed Industrial Base Tissue Papers

Joana Costa Vieira  1 , António de O Mendes  1 , Marcelo Leite Ribeiro  1   2 , André Costa Vieira  3 , Ana Margarida Carta  4 , Paulo Torrão Fiadeiro  1 , Ana Paula Costa  1
Affiliations

FEM Analysis Validation of Rubber Hardness Impact on Mechanical and Softness Properties of Embossed Industrial Base Tissue Papers

Joana Costa Vieira et al. Polymers (Basel). .

Abstract

The embossing operation is one of the processes of tissue paper converting. The embossing parameters influence the final properties of tissue products, such as mechanical, softness, and bulk. In this study, the influence of the rubber hardness used against the embossing steel rolls with a pattern created by intaglio engraving was studied. Three different configurations of rubber plates stacking, each plate with different hardness, were studied. After embossing, mechanical properties, softness, and bulk were evaluated to analyze the effect of rubbers hardness on these properties. Furthermore, a Finite Element Model of the embossing operation was used that considered the same rubber plates stacking configurations used in experiments, and it was able to replicate the experimental results. This work led us to conclude that the configuration where two rubber plates with different hardness, where the rubber plate with higher hardness is in contact with the tissue paper sheet, has shown to be the best solution to obtain higher softness. These findings support the use of embossing operations rubber rolls with a low hardness internal layer and a high hardness external layer in industry. Thus, finite element models were also shown to be reliable tools to virtually test other configurations, such as, for example, three or more rubber plates with different hardness. Since embossing is one of the tissue paper transformation operations with the greatest impact on the key properties of the final product, this study allows the producer to optimize them by varying the hardness of the rubber roll, as well as its configuration.

Keywords: FEM simulation; embossing prototype; mechanical properties; optical visual inspection; rubber hardness; softness characterization; tissue paper.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Image of the industrial base tissue paper and the inset showing the crepe structure in a small magnified area.
Figure 2
Figure 2
Images of the used rubber plates.
Figure 3
Figure 3
Schematic of the embossing process with different rubber plate hardness configurations: (a) configuration 1; (b) configuration 2; and (c) configuration 3.
Figure 4
Figure 4
Embossing patterns: (a) deco embossing, and (b) micro embossing.
Figure 5
Figure 5
Model dimensions and boundary conditions.
Figure 6
Figure 6
Global views of tissue paper embossed with the different rubber hardness using configuration 1: (a) 48 Sh-A (deco—front side); (b) 48 Sh-A (deco—back side); (c) 48 Sh-A (micro—front side); (d) 48 Sh-A (micro—back side); (e) 60 Sh-A (deco—front side); (f) 60 Sh-A (deco—back side); (g) 60 Sh-A (micro—front side); (h) 60 Sh-A (micro—back side); (i) 75 Sh-A (deco—front side); (j) 75 Sh-A (deco—back side); (k) 75 Sh-A (micro—front side); and (l) 75 Sh-A (micro—back side).
Figure 7
Figure 7
Bulk evolution with the increase in rubber hardness.
Figure 8
Figure 8
Tensile index behavior with the increase in rubber hardness.
Figure 9
Figure 9
Handfeel comportment with the increase in rubber hardness.
Figure 10
Figure 10
Global views of tissue paper embossed with the different combinations of rubber hardness of configuration 2: (a) 60_48 Sh-A (deco—front side); (b) 60_48 Sh-A (deco—back side); (c) 60_48 Sh-A (micro—front side); (d) 60_48 Sh-A (micro—back side); (e) 75_48 Sh-A (deco—front side); (f) 75_48 Sh-A (deco—back side); (g) 75_48 Sh-A (micro—front side); and (h) 75_48 Sh-A (micro—back side).
Figure 11
Figure 11
Bulk, tensile index, and handfeel results for deco embossing and configuration 2 rubber hardness conjugation.
Figure 12
Figure 12
Bulk, tensile index, and handfeel results for micro embossing and configuration 2 rubber hardness conjugation.
Figure 13
Figure 13
Global views of tissue paper embossed with the different combinations of rubber hardness of configuration 3: (a) 48_60 Sh-A (deco—front side); (b) 48_60 Sh-A (deco—back side); (c) 48_60 Sh-A (micro—front side); (d) 48_60 Sh-A (micro—back side); (e) 48_75 Sh-A (deco—front side); (f) 48_75 Sh-A (deco—back side); (g) 48_75 Sh-A (micro—front side); and (h) 48_75 Sh-A (micro—back side).
Figure 14
Figure 14
Bulk, tensile index, and handfeel results for deco embossing and configuration 3 rubber hardness conjugation.
Figure 15
Figure 15
Bulk, tensile index, and handfeel results for micro embossing and configuration 3 rubber hardness conjugation.
Figure 16
Figure 16
Results obtained for handfeel (HF) with the rubber hardness to the combined 2-ply deco and micro embossed samples.
Figure 17
Figure 17
Deco die 75 Sh-A (CR PR), Plastic field.
Figure 18
Figure 18
Deco die 60 Sh-A (SBR PR), Plastic field.
Figure 19
Figure 19
Deco die 48 Sh-A (NR BG), Plastic field.
Figure 20
Figure 20
Micro die 75 Sh-A (CR PR), Plastic field.
Figure 21
Figure 21
Micro die 60 Sh-A (SBR PR), Plastic field.
Figure 22
Figure 22
Micro die 48 Sh-A (NR BG), Plastic field.
Figure 23
Figure 23
Deco die 75_48 Sh-A (CR PR/NR BG), Plastic field.
Figure 24
Figure 24
Deco die 60_48 Sh-A (SBR PR/NR BG), Plastic field.
Figure 25
Figure 25
Micro die 75_48 Sh-A (CR PR/NR BG), Plastic field.
Figure 26
Figure 26
Micro die 60_48 Sh-A (SBR PR/NR BG), Plastic field.
Figure 27
Figure 27
Deco die 48_75 Sh-A (NR BG/CR PR), Plastic field.
Figure 28
Figure 28
Deco die 48_60 Sh-A (NR BG/SBR PR), Plastic field.
Figure 29
Figure 29
Micro die 48_75 Sh-A (NR BG/CR PR), Plastic field.
Figure 30
Figure 30
Micro die 48_60 Sh-A (NR BG/SBR PR), Plastic field.
See this image and copyright information in PMC

References

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