Multi-ply fibrous web structure and its manufacture

• US 4,376,671 A
• Filed: 10/05/1981
• Issued: 03/15/1983
• Est. Priority Date: 05/15/1980
• Status: Expired due to Term

• Current Assignee: James River Paper Company, Inc.
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Schulz, Galyn A.
• Primary Examiner(s): Wityshyn, Michael G.
• Application Number:
  US06/308,948
• Time in Patent Office: 526 Days
• Field of Search: 156/199, 156/292, 156/551, 156/553, 156/555, 156/582, 156/549, 156/471, 428/166, 428/198, 162/296, 162/362
• US Class Current: 156/549
• CPC Class Codes: B31F 1/07 Embossing , i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profilesB31F1/128 takes precedence; corrugating B31F1/20; embossing in combination with printing B41F19/02, B41M1/24; typewriters for embossing B41J3/38; stamping in combination with deforming B41K3/36
• CPC Class Codes: B31F 2201/0733 Pattern
• CPC Class Codes: B31F 2201/0738 Cross sectional profile of the embossments
• CPC Class Codes: B31F 2201/0758 Characteristics of the embossed product
• CPC Class Codes: B31F 2201/0766 the layers being superposed tip to tip
• CPC Class Codes: B31F 2201/0769 the layers being shifted
• CPC Class Codes: B31F 2201/0787 Applying adhesive
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: D21H 27/40 at least one of the sheets being non-planar, e.g. crêped crêping or corrugating paper B31F
• CPC Class Codes: Y10T 156/1727 Plural indefinite length or running length workpieces
• CPC Class Codes: Y10T 156/1732 Fluid applied to plural workpieces
• CPC Class Codes: Y10T 156/1737 Discontinuous, spaced area, and/or patterned pressing
• CPC Class Codes: Y10T 156/1741 Progressive continuous bonding press [e.g., roll couples]

Abstract

In the manufacture of a multi-ply fibrous web structure, each of a pair of plies of fibrous web material is provided with a pattern of relatively deep, primary, spot embossments each adherent to the opposite ply and surrounded by a pattern of relatively shallow, secondary, non-adherent spot embossments.

Claims

1. Apparatus for fabricating multi-ply embossed web structure, comprising:

first and second embossing rolls, each having a pattern of mutually, relatively widely spaced first identical protuberances and a pattern of mutually, relatively closely spaced second identical protuberances in the spaces between said first protuberances, said rolls being constructed and arranged so that said closely spaced protuberances on one roll mesh with the like protuberances on the other roll and to form a ply bonding nip between confronting ones of said first protuberances only;

backup rolls for said embossing rolls cooperative therewith to form corresponding embossments in each of a pair of fibrous webs fed therebetween;

means for applying adhesive solely to the distal ends of embossments formed in at least one of said webs by said relatively widely spaced first protuberances; and

means for adhesively joining to the opposite one of said webs the distal ends of embossments formed in said webs by said relatively widely spaced first protuberances.

4. The apparatus of claim 1, 2, or 3, wherein said first protuberances are so dimensioned as to form an embossment from about 0.040 inch to about 0.090 inch in depth, said second protuberances are so dimensioned as to form an embossment from about 0.015 inch to about 0.050 inch in depth.

5. The apparatus of claim 1, 2, or 3, wherein said first protuberances are mutually spaced a first uniform distance, and said second protuberances are mutually spaced a second uniform distance.

6. The apparatus of claim 4, wherein said first protuberances are mutually spaced a first uniform distance, and said second protuberances are mutually spaced a second uniform distance.

2. Apparatus for fabricating multi-ply embossed web structure, comprising:

first and second embossing rolls, each having a pattern of mutually, relatively widely spaced first identical protuberances of a first radial extent and a pattern of mutually, relatively closely spaced second identical protuberances of a second radial extent less than the recited first protuberances in the spaces between said first protuberances, said rolls being constructed and arranged to form a ply bonding nip between confronting ones of said first protuberances only;

backup rolls for said embossing rolls cooperative therewith to form corresponding embossments in each of a pair of fibrous webs fed therebetween; and

means for applying adhesive to the distal ends of embossments formed in at least one of said webs by said first protuberances, prior to entry of said webs into said ply bonding nip.

3. Apparatus for fabricating multi-ply embossed web structure, comprising:

first and second embossing rolls, each having a pattern of mutually, relatively widely spaced first identical protuberances of a first radial extent and a pattern of mutually, relatively closely spaced second identical protuberances of a second radial extent less than the recited first protuberances in the spaces between said first protuberances, said rolls being constructed and arranged to form a ply bonding nip between confronting ones of said aligned first identical protuberances only;

backup rolls for said embossing rolls cooperative therewith to form corresponding embossments in each of a pair of fibrous webs fed therebetween;

means for applying adhesive to the distal ends of embossments formed in each of said webs by said first identical protuberances, prior to entry of said webs into said ply bonding nip; and

means for feeding a creped fibrous web into the ply bonding nip adhesively to join said pair of embossed webs solely at through said distal ends of said embossments formed by said first protuberances.