Method and apparatus for contour multi-level embossing with perforation bonding in selected spaced locations
First Claim
1. An apparatus for providing perforation bonding and embossing of multiple plies of web material, comprising:
- at least two backup rolls; and
at least two embossing rolls, each of said embossing rolls positioned adjacent a respective one of said backup rolls so as to create an interference between said rolls during rotation to emboss said web material which is fed therethrough, each of said embossing rolls further positioned adjacent to one another so as to create an interference between said embossing rolls for perforation bonding said web material which is fed therethrough in a nip region, said embossing rolls including;
a plurality of embossing elements for forming an embossed pattern in the web material, said embossing elements having at least two different heights arranged in an embossing pattern for embossing said web material; and
a plurality of perforation elements, said perforation elements being the highest element on said embossing rolls for perforation bonding and embossing said web material;
wherein said perforation elements of at least two of said embossing rolls interfere with one another in said nip region such that the plies of the web material are perforation bonded to one another.
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Accused Products
Abstract
An embossing apparatus and method which provides a better embossed appearance and eliminates undesired roughness on the backside of the web material. Two plies are multilevel embossed between rigid engraved rolls and backup rolls, which may be either engraved or smooth. One rigid roll has embossing elements of varying heights and perforation elements, which run in a side-by-side relationship with the corresponding perforation elements on the opposing rigid roll in a nip region of the apparatus. The multiple plies are perforation bonded between the perforation elements, which are preferably the two highest elements, thus reinforcing the other multi-level embossed pattern formed in between the perforation bonds. The embossed patterns impart a quilt-like contoured appearance to the finished product.
68 Citations
23 Claims
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1. An apparatus for providing perforation bonding and embossing of multiple plies of web material, comprising:
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at least two backup rolls; and at least two embossing rolls, each of said embossing rolls positioned adjacent a respective one of said backup rolls so as to create an interference between said rolls during rotation to emboss said web material which is fed therethrough, each of said embossing rolls further positioned adjacent to one another so as to create an interference between said embossing rolls for perforation bonding said web material which is fed therethrough in a nip region, said embossing rolls including; a plurality of embossing elements for forming an embossed pattern in the web material, said embossing elements having at least two different heights arranged in an embossing pattern for embossing said web material; and a plurality of perforation elements, said perforation elements being the highest element on said embossing rolls for perforation bonding and embossing said web material; wherein said perforation elements of at least two of said embossing rolls interfere with one another in said nip region such that the plies of the web material are perforation bonded to one another. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. An apparatus for providing perforation bonding and multiple levels of embossing of multiple plies of a fibrous web material, comprising:
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at least two backup means for directing respective fibrous webs to be embossed and perforation bonded; at least two embossing means having embossing elements of at least two different heights for embossing said fibrous web material at multiple levels, each of said embossing means positioned adjacent a respective one of said backup means so as to create an interference between said rolls during rotation to create an embossed pattern in said web material which is fed therethrough, each of said embossing means further being positioned adjacent to one another so as to create an interference for embossing said fibrous web material which is fed through a nip region between said embossing means; and a perforation bonding means rigidly attached to said embossing means for creating perforation bonds in said fibrous web material at predetermined intervals to reinforce said embossments formed in said fibrous web material without melting said fibrous web material as said fibrous web material passes through said nip region. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method for embossing multiple fibrous plies comprising the steps of:
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directing at least two continuous fibrous webs of material through an embossing apparatus; forming at least two levels of patterns on one of said continuous fibrous webs of material by embossing said material between a first and second roll, said second roll including a plurality of embossing elements; forming at least two levels of patterns on another one of said continuous fibrous webs of material by embossing said material between a third and fourth roll, said third roll including a plurality of embossing elements; and perforation bonding said at least two continuous fibrous webs of material between said second roll and said third roll to bond said continuous fibrous webs of material to one another. - View Dependent Claims (21, 22, 23)
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Specification