BRPI0611108A2 - embossed product including distinct and linear embossing and method for its manufacture - Google Patents

Abstract

An apparatus and method for producing an embossed product, the apparatus including a first embossing member (20) and a second embossing member (30) . The first embossing member has a plurality of discrete embossing elements (410) disposed in a first pattern (400) . The second embossing member has a plurality of second embossing elements (510) including at least one linear embossing element. The second embossing elements are disposed in a second pattern (500) such the first pattern and the second pattern nest together. The present invention also includes an embossed web including at least one discrete embossment and at least one linear embossment.

Description

DRYED PRODUCT INCLUDING DISTINCT AND LINEAR DRILLS AND METHOD FOR THEIR MANUFACTURING

FIELD OF INVENTION

The present invention relates to an improved apparatus and process for the production of matted products. The present invention also relates to blanket products produced by the use of improved process and apparatus.

BACKGROUND OF THE INVENTION

Embossing of blankets, such as paper blankets, is well known in the art. Embossing of blankets can provide improvements to the blanket due to swelling, increased water retention capacity, improved aesthetics and other benefits. Both single-layer and multi-layer (or multilayer) blankets are known in the art and can be embossed. Multilayer paper webs are webs that include at least two layers overlapped face to face to form a laminate.

During a typical embossing process, a blanket is fed through a socket formed between generally parallel and juxtaposed rollers. Embossing elements in the rollers compress and / or deform the mat. If a multilayer product is being formed, two or more layers are fed through the socket and regions of each layer are placed in a contact relationship with the opposite layer. The embossed regions of the layers can produce an aesthetic pattern and provide a means for joining and emanating the layers in face-to-face contact. Embossing is typically performed by one of two processes; button embossing or button embossing. Button-to-button embossing consists of generally parallel and juxtaposed axis rollers to form a fit between the embossing elements in opposite rollers. Nested embossing typically consists of embossing elements of one roll interlaced between the embossing elements of the other roll. Examples of button-to-button and nested embossing are illustrated in the prior art by U.S. Patent Nos. 3,414,459 issued December 3, 1968 to Wells; 3,547,723 issued December 15, 1970 to Gresham; 3,556,907 granted January 19, 1971 to Nystrand; 3,708,366 granted January 2, 1973 to Donnelly; 3,738,905 granted June 12, 1973 to Thomas; 3,867,225 granted February 18, 1975 to Nystrand; 4,483,728 issued Nov. 20, 1984 to Bauernfeind; 5,468,323 issued November 21, 1995 to McNeil; 6,086,715 issued June 11, 2000 to McNeil; 6,277,466 of August 21, 2001; 6,395,133 issued May 28, 2002 and 6,846,172 B2 issued to Vaughn and others January 25, 2005.

Button-to-button embossing generally produces a blanket comprising padded regions which may increase the thickness of the product. However, cushioned regions tend to sag under pressure due to lack of support. Consequently, the benefit of thickness is typically lost during the remainder of the conversion operation and subsequent packaging, decreasing the benefit of padded appearance and / or thickness sought by embossing.

Nested embossing has proven in some cases to be a more convenient process for producing products that have a softer, softer appearance that can be maintained throughout the rest of the converting process, including packaging. With the co-embossing embossing of a multilayer product, one layer has a male pattern, while the other layer has a female pattern. As the two layers move through the engagement of the embossing rollers, the patterns are interlaced. The nesting embossing aligns the norolo knob embossing ridges with the low areas on the female embossing roll. As a result, embossed locations produced on one layer provide support for embossed locations on the other layer.

Another type of embossing, deep cooldering embossing, was developed and used to provide unique characteristics of the embossed blanket. Deep nesting embossing refers to embossing that uses paired embossing elements, where the protrusions of the different embossing elements are coordinated such that the protrusions of a embossing element fit into the space between the protrusions of the other embossing element. While many deep nesting embossing processes are configured such that the embossing members of the opposing embossing members do not touch each other or touch the surface of the opposite embossing member, modalities are contemplated where the deep embossing embossing process includes tolerance such that embossing touch each other or touch the surface of the opposite embossing member when engaged.

(Of course, in the effective process, the embossing members generally do not touch each other or the embossing member because the blanket is disposed between the embossing members.) Deep nesting embossing techniques are described in US Pat. 5,686,168 issued to Laurent et al. On November 11, 1997; 5,294,475 issued to McNeil on March 15, 1994; US Serial Patent Application No. 11 / 059,986; US Serial No. 10 / 700,131 filing order and US Serial No. 60 / 573,727 provisional order.

While these deep nesting technologies have been useful, it has been observed that when producing deep nested embossed patterns, the resultant coating may lose some of its strength and / or softness due to the embossing process. In addition, some deep nesting embossing patterns can substantially weaken the blanket or even tear the blanket while the blanket is being embossed. In addition, deep-nesting embossing patterns may in some cases actually decrease the acceptance of the product making the product appear somewhat harsh or rough.

Accordingly, it would be desirable to provide a embossing process or apparatus that provides at least some of the benefits of prior art embossing methods, while reducing at least some of the negative points that may be associated with such processes. For example, it may be convenient to provide a shearing apparatus and a method for embossing a blanket that provides improved softness over prior art embossing methods. In addition, it may be convenient to provide a embossing process and / or apparatus that provides a more aesthetically pleasing pattern to the embossed mat. In addition, it may be convenient to provide a defrosting process and / or apparatus that provides less mat damage than prior art methods and apparatus. Still further, it may be convenient to provide a web of material which has been subjected to the improved embossing process.

SUMMARY OF THE INVENTION

To provide a solution to some of the prior art problems, the present invention provides an apparatus and method for producing an embossed product. The apparatus includes a first embossing member and a second embossing member. The first embossing member has a first surface and a plurality of first embossing elements extending from the first surface. The plurality of first embossing elements are distinct embossing elements and are arranged in a first pattern. The second embossing member has a second surface and a plurality of second embossing elements extending from the second surface. The plurality of second embossing elements include at least one linear embossing element and are arranged in a second pattern wherein the second pattern is coordinated with the first pattern. The first debonding member and the second embossing member are aligned in detail so that the respective first coordinate pattern and second pattern nest together such that they engage each other to a depth greater than about 0.01 mm.

In another embodiment, the present invention includes apparatus for producing an embossed product comprising a first embossing member having a first surface and a plurality of first embossing elements extending from the first surface. The plurality of first embossing elements are distinct embossing elements and are arranged in a first standard having at least one first single pattern unit. Each first embossing element has a first distal end and a first distal end area, where the total area of the first distal end areas of the distinct embossing elements in the first single pattern unit is less than about 5.0 cm 2. The apparatus also includes a second embossing member having a second surface and a plurality of second embossing elements extending from the second surface. The plurality of second embossing elements are linear embossing elements and are arranged in a second pattern having at least one second single pattern unit. Each second embossing element having a second distal end and a second distal end area, wherein the total area of the second distal end areas of the linear embossing elements in the second single pattern unit is less than about 10 cm 2, and wherein the second pattern It is coordinated with the first pattern so that when engaged, the first single pattern unit and the second single pattern unit make up a single pattern defrosting unit.

The present invention also includes the methods for molding blanket materials using the above exposed apparatus.

Furthermore, the present invention provides a blanket product including one or more layers having a first and a second side. The matting product includes a plurality of distinct embossings extending from the first side to the second side. At least a linear molding extends from the second side to the first side, wherein the blanket product has an embossing height greater than about 650 μπι.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a schematic side view of an embodiment of an apparatus that can be used to perform deep nesting embossing of the present invention.

Figure 2 is an enlarged side view of the socket formed between the embossing rollers of the apparatus shown in Figure 1.

Figure 3 is a schematic side view of an embodiment of an apparatus that can be used to perform deep nesting embossing of the present invention. Figure 4 is a schematic side view of an alternative apparatus that can be used to perform deep nesting embossing of the present invention. .

Figure 5 is a side view of the clearance between the engaging embossing rollers of the deep nesting embossing apparatus of the present invention.

Figure 6 is a side view of one embodiment of the embossed paper product produced by the apparatus or process of the present invention.

Figure 7 is a plan view of an example of an embossing pattern including distinct embossing protuberances.

Figure 8 is a plan view of an example of an embossing pattern including non-distinct embossing protuberances having linear portions. The pattern shown in Figure 8 is an example of a pattern that can be complementary to the distinct embossing protrusion pattern of Figure 7.

Figure 9 is a plan view of an example how embossing elements of an embossing pattern similar to that shown in Figure 7 may embed with embossing elements of a embossing pattern similar to that shown in Figure 8.

Figures 10a to 10c are examples of linear deformation elements.

Figure 11 is a plan view of an example of how embossing elements of one pattern can embed with embossing elements of another embossing pattern. Figure 12 is a plan view of an alternative example of a embossing pattern including undistinguished embossing protuberances. having lineal portions. The pattern shown in Figure 12 is an example of a pattern that may be complementary to a pattern of distinct embossing protuberances similar to that of Figure 7.

Figure 13 is a plan view of an example how embossing elements of an embossing pattern similar to that shown in Figure 7 may embed with embossing elements of a embossing pattern similar to that shown in Figure 12.

Figure 14 is a plan view of an example of how the embossing elements of a linearly embossed embossing pattern and embossing pattern with distinct defrosting elements would appear to be recessed together and shown in a single plane.

DETAILED DESCRIPTION OF THE INVENTION

It has been found that a new embossing apparatus can provide improvements in deep-nesting embossing processes and blankets that are subjected to such deep-nesting embossing processes. In particular, it has been found that in an apparatus for performing a deep nesting embossing process, it may be advantageous that at least one of the embossing members includes at least one non-distinct embossing element. As used herein, the term "distinct" with reference to embossing elements means that the embossing element (which may be interchangeably referred to herein as a embossing protrusion or protrusion) is not contiguous with each other embossing element but is instead separated from all other embossing elements. embossing elements at some distance. Although distinct embossing elements may be of any size or shape, they are typically generally circular or oval in cross section at their distal end (i.e., the farthest end from the surface from which the embossing element extends). If generally circular in cross section, the distinct embossing elements typically have a distal end diameter of less than about 15mm, less than about 7.5mm, less than about 5.0mm, less than about 3.0 mm, less than about 1.00 mm, between about 1.0 mm and about 15 mm, or any number within this range. In embodiments where the distinct embossing elements are non-circular, the distinct embossing elements may have a larger length dimension (i.e. the longest dimension at the distal end parallel to the surface from which the embossing element extends) and a smaller length dimension ( that is, the shortest dimension at the distal end parallel to the surface from which the defrosting element extends). The above dimensions with respect to the diameter of the distal end of distinct generally circular debarking elements are applicable to the greater length at the distal end of distinct non-circular embossing elements. In addition, in such cases, in order not to be considered linear, the distinct embossing elements will have a ratio of the largest length to the smallest length less than about 3.5: 1, less than about 3: 1, less than fence 2, 5: 1, from about 3.5: 1 to about 1: 1, or any reason within the range.

As used herein, the term "continuous" refers to a embossing pattern including a embossing element that extends continuously over at least one path without breaking or interrupting. That is, you can follow through the entire continuous embossing pattern without ever having to cross a break or break in the pattern.

As used herein, the term "linear" as refers to embossing elements means that the embossing element has a dimension in a direction parallel to the surface or plane from which it extends that is longer than any other dimension of the other parallel element. to the surface or plane from which it extends. More specifically, the term linear refers to embossing elements that have a length and a width, where the length to width ratio is at least about 4: 1, at least about 5: 1 or at least about 10: 1. In addition, a linear element could be continuous as described herein. (For the purposes of this application, the length of a linear embossing element is measured along a path that substantially corresponds to a longitudinal centerline of the embossing element and width is measured generally perpendicular to the longitudinal centerline. If the linear embossing element is in the form of a sketch of a shape, such as a square, the length of the linear embossing element is taken along the longitudinal centerline of the embossed portions of the linear embossing element (e.g., the portions that make up the shape outline) as opposed to the centerline longitudinal area of the embossing element including non-embossed portions, so the length would generally correspond to the length of the outline outline of the shape formed by the linear embossing elements as opposed to a distance that divides or otherwise cuts through a portion of the shape. An example of measuring length This linear element is shown in Figure 8.) In certain embodiments, it may be convenient for the width of the linear embossing element to be less than about 15.0 mm, less than about 7.5 mm, less than about 5 mm. .0 mm, less than about 2,5 mm, less than about 1,0 mm, between about 1,0 mm and about 15,00 mm, or any number within this range.

The linear term does not require that the debonding element be of any specific shape other than that set forth herein, and it is considered that such linear embossing elements may include generally straight lines or curved lines or combinations thereof. In addition, a "linear" element need not be uniform in width and / or height. (For purposes of this application, the width measurement used to determine the length-to-width ratio is the widest (or largest width measurement) taken over the length of the embossing element.) In addition, linear embossing elements may form patterns and / or formats that repeat or do not repeat. In this way, the pattern, if any, formed by the linear defrosting elements may be regular or non-regular as desired.

In certain embodiments, it may be convenient for the apparatus to include an embossing member (e.g., a sheet or roll) having distinct embossing elements which have linear embossing elements from a corresponding sheet or roller. In other embodiments, it may be convenient for the apparatus to include two de-molding members each having linear embossing elements which fall together. In still other embodiments, it may be convenient for the apparatus to include embossing members, one or more of which have a combination of discrete and linear embossing elements.

As noted above, the use of such an apparatus and / or a process including the apparatus may provide an improved deep nesting screw product. For example, the use of such a device and method may provide the mat product with improved strength, softness, aesthetics and / or other advantageous features such as improved print characteristics, etc. (While much of the disclosure disclosed herein refers to the embossing apparatus including It should be understood that the foregoing information also applies to any other type of embossing platform or mechanism from which embossing elements may extend, such as rollers, cylinders, plates and the like, and the invention of the apparatus or method of using the apparatus shall not be limited. in any way to a specific apparatus unless expressly stated in the appended claims.)

Figure 1 shows an embodiment of the apparatus 10 of the present invention. Apparatus 10 includes a pair of rollers, first embossing roll 20 and second embossing 30. (It should be noted that the embodiments shown in the Figures are only exemplary embodiments and other embodiments are certainly considered. For example, embossing rollers 20 and 30 of the embodiment shown in FIG. Figure 1 could be replaced by any other embossing members such as sheets, cylinders or other suitable web embossing equipment, and additional equipment and steps not specifically described herein may be added to the apparatus and / or process of the present invention. ) Defrosting rollers 20 and 30 are arranged adjacent to each other to provide a groove 40. Rollers 20 and 30 are generally configured to be rotatable on an axes, the geometry axes 22 and 33 respectively of rollers 20 and 30 are typically generally parallel to each other. The apparatus 10 may be contained in a typical embossing device housing. Each roll has an outer surface 25 and 35 comprising a plurality of protrusions or embossing elements 50 and 60 (shown in more detail in Figure 2) arranged in a non-random pattern. Embossing rollers 20 and 30, including roll surface 25 and 35 as well as embossing elements 50 and 60, may be made of any material suitable for the desired embossing process. Such materials include, without limitation, steel and other metals, ebonite, and hard rubber or a combination thereof. As shown in Figure 1, the first and second release rollers 20 and 30 provide a socket 40 through which a blanket 100 may pass. In the embodiment shown, the blanket 100 is composed of the first layer 80 and the second layer 90 and is shown by passing through the socket 40 in the direction of the machine, DM.

Figure 2 is an enlarged view of the portion of apparatus 10 labeled 2 in Figure 1. Figure shows a more detailed view of the combined blanket 100 passing through the socket 40 between the first embossing roll 20 and the second embossing roll 30. As can be seen from Figure 2 , the first embossing roll 20 includes a plurality of first embossing elements 50 extending from the surface 25 of the first embossing roll 20. The second embossing roll also includes a plurality of second embossing elements 60 extending outwardly from the surface 35 of the (It should be noted that when embossing elements 50 and / or 60 are described as extending from a surface of a embossing member, embossing elements may be integral with the embossing member surface or may be separate elements which attached to the surface of the embossing member.) As the layers of the blanket 80 and 90 are passed through the and 40, are nested and macroscopically deformed by the embedding of the first embossing elements 50 and second embossing elements 60. The embossing shown is deep nested embossing, as described herein, because the first embossing elements 50 and second embossing elements 60 embed with each other. example, like gear teeth. Thus, the resultant blanket 100 is embossed and deeply nested, as will be described in more detail below, and includes plurality of undulations that may add volume and gauge to blanket 100.

Figure 3 shows an alternative embodiment of the process of the present invention wherein the first layer 80 and the second layer 90 of the resulting mat 100 are joined between the marrying roll 70 and the first embossing roll 20. The layers 80 and 90 may be however, typically an adhesive delivery system is used to apply adhesive to one or both layers 80 and 90 prior to the passage of the layers between the groove 75 formed between the marrying roll 70 and the first coating roll. embossing 20. The combined mat 100 is then passed through the socket 40 formed between the first embossing roller 20 and the second embossing roller 30 where it is embossed.

In yet another possible embodiment of the present invention, as shown in Figure 4, the layers 80 and 90 are passed through the socket 40 formed between the first embossing roll 20 and the second embossing roll 30 where the layers are placed in contact with each other and embossed. At this stage, it is also common to join the sheets together using conventional joining methods as an adhesive application system, but, as noted above, other joining methods may be used. The combined mat 100 is then passed through the socket 75 between the first embossing roll 20 and the marrying roll 70. This step is often used to ensure that the layers 80 and 90 of the blanket 100 are securely bonded before the blanket 100 is directed to further processing or winding steps.

It should be noted that with respect to any of the methods described herein, the number of layers is not critical and may be varied as desired. Accordingly, it is within the scope of the present invention to use methods and equipment which provide a matting product having a single layer, two layers, three layers, four layers or any other number of layers suitable for the intended end use. In each case, it is understood that a person skilled in the art will be able to add or remove equipment necessary to provide / or combine the different number of layers. In addition, it should be noted that the layers of a multi-layer mat product need not be the same in composition or other characteristics. Thus, the different layers may be made of different materials, such as from different fibers, different combinations of fibers, natural and synthetic fibers or any other combination of materials composing the base layers. In addition, the blanket 100 may include one or more layers of a cellulosic blanket and / or one or more layers of a blanket made from non-cellulose materials including polymeric materials, other natural or synthetic starch-based materials suitable for forming fibrous webs. In addition, one or more of the layers may include a non-woven blanket, a woven blanket, a strong fabric, a film, a sheet or any other material generally similar to the flat sheet. In addition, one or more of the layers may be embossed with a pattern that is different than one or more of the other layers or may have no embossing.

In the deep nesting embossing process, as shown in Figure 5, the embossing members 50 and 60 of the embossing members (in this case embossing plates 21 and 31) engage such that the distal end 110 of the first embossing members. embossing50 extends into space 220 between the second embossing elements 60 of the second embossing roll 30 beyond the distal end 210 of the second embossing elements 60. Therefore, the distal ends 210 of the second embossing elements 60 should extend also into the space 120 between the first embossing elements 50 of the first embossing roll 20 beyond the distal end 110 of the first embossing elements 50. The depth of the coupling D may vary depending on the desired embossing level in the final product and may be any distance greater than zero. Typical deep nesting modalities have a depth D greater than about 0.01 mm, greater than about 0.05 mm, greater than about 1.0 mm, greater than about 1.25 mm, greater than about 1.5 mm, greater than about 2.0 mm, greater than about 3.0 mm, larger than about 4.0 mm, greater than about 5.0 mm, between about 0.01 mm and about 5.0 mm or any number within this range. (It should be noted that while the description in that paragraph describes certain relationships between embossing members 50 and 60 disposed on embossing members and embossing plates 21 and 31, the same engaging characteristics apply to embossing members 50 and 60 which are disposed on embossing members. non-sheet embossing, but instead take a different form, such as embossing rollers 20 and 30 shown in Figure 1.)

In certain embodiments, as shown, for example, in Figure 5, at least some of the first embossing elements 50 and / or second embossing elements 60, whether linear or distinct, may have at least one transition region 130 having a curvature decurvature radius. r. The transition region 130 is disposed between the distal end of the embossing element and the side wall of the embossing element. (As can be seen from Figure 5, the distal end of the first embossing element is labeled 110, while the sidewall of the first embossing element is labeled 115. Similarly, the distal end of the second embossing element is labeled 210, while one of the sidewalls of the second embossing element. embossing element is labeled 215.) The curvature radius of curvature r is typically greater than about 0.075mm. Other embodiments have radii greater than 0.1mm, greater than 0.25mm, greater than about 0.5mm, between about 0.075mm and about 0.5mm, or any number within this range. The radius of curvature of curvature r of any specific transition region is typically less than about 1.8 mm. Other embodiments may have embossing elements with transitional regions 130 having radii of less than about 1.5 mm, less than about 1.0 mm, between about 1.0 mm and about 1.8 mm or any number within the range. (Although Figure 5 shows an example of two recessed deburring plates, embossing plate 21 and deburring plate 31, the information set forth herein with respect to embossing elements 50 and 60 is applicable to any type of platform or embossing mechanism from from which embossing elements can extend, such as rollers, cylinders, plates and the like.)

The "rounding" of the transition region 130 typically results in a circular arc rounded transition region, 130, from which a curvature decurvature radius is determined as a traditional arc decurvature radius. The present invention, however, also considers transition region configurations that approach an arc rounding by having the edge of transition region 130 removed by one or more straight line or irregular cut lines. In such cases, the radius of curvature of curvature r is determined by measuring the radius of curvature of a circular arc that includes a portion approaching the curve of the transitioning region 130.

In other embodiments, at least a portion of the distal end of one or more of the embossing elements other than transition regions 130 may be generally nonplanar, including for example generally curved or rounded. Thus, the entire surface of the embossing element covering between side walls 115 or 215 may be non-flat, for example, curved or rounded. The non-flat surface may assume any shape, including, but not limited to, smooth or curved curves, as described above, which are actually a straight line number or irregular cuts to provide the non-flat surface. An example of the embossing element is embossing element 62 shown in Figure 5. While not wishing to be bound by theory, it is believed that rounding of transition regions130 or any portion of the distal ends of embossing elements can provide the resulting paper with more embossing. soft and few rough edges. In this way, the resulting paper may have a smoother and / or softer feel and appearance.

Figure 7 shows an example of a first embossing pattern 400 including discrete embossing elements 410. The distinct embossing elements 410 are separate from each other and form what, in this particular case, appear to be generally circular protuberances that extend from surface 420 of the plate, roll or other structure in which the pattern 400 is arranged. Although a specific repeating design is shown in Figure 7, it is just an example of a embossing pattern 400 including at least one distinct embossing element 410. Any other desired pattern could be chosen, including non-regular and / or non-repeating patterns. In addition, embossing pattern 400 could include both distinct embossing elements and non-distinct embossing elements. Still further, the pattern 400 could include linear embossing elements in addition to the distinct and / or non-distinct embossing elements 400.

Figure 8 shows an example of a second embossing pattern 500 that includes linear embossing elements510 as defined herein. The linear embossing elements510 in the specific pattern shown form the boundaries of a generically square-shaped area. As can be seen, linear embossing elements 510 have a length dimension L (the longest dimension as defined herein) parallel to the surface 520 from which they extend which is longer than their width dimension W (as defined herein) which is the dimension generally perpendicular to the length dimension L of the deformation member 510 (at the point at which the width dimension is drawn) and also parallel to the surface 520 from which it extends. More specifically, the linear deforming elements 510 have a length to width W ratio of at least about 4: 1, at least about 5: 1 or at least about 10: 1. Although the length L and width W of the linear embossing elements 510 may be any suitable number, in certain embodiments, it may be convenient that the width W of the linear embossing element is less than about 15 mm, less than about 7.5 mm, smaller. than about 5.0 mm, less than about 2.5 mm, less than about 1.0 mm, between about 1.0 mm and about 15 mm, or any number comprised therein.

As noted above, the term linear does not require embossing element 510 to be of any specific shape and it is envisaged that such linear embossing elements 510 may include generally straight lines or curved lines or combinations thereof. In addition, as mentioned above, the linear element need not be uniform in width W. Some non-limiting examples of different possible linear embossing elements with non-uniform widths are shown in Figures IOB to C, 11, 12 and 13.

Linear embossing elements 510 may form repeating or non-repeating patterns and / or shapes. Thus, the pattern, if any, formed by the linear embossing elements 510 may be regular or non-regular as desired. In addition, the specific pattern 500 in which linear embossing elements 510 are included may also include distinct embossing elements and non-distinct embossing elements. Also, as shown in Figure 8, the second linear embossing pattern 500 may include a number of different linear embossing elements 510 that will be separated from each other to form the desired pattern 500.

As also shown in Figure 8, linear embossing elements 510 may be shaped such that they include an enclosed or at least partially closed region, such as region 530. In the specific, linear embossing pattern 500 shown, linear embossing elements510 are It is generally in the shape of a square outline. Internal to each linear embossing element 510 is the enclosed region 530. Of course, any other linear embossing element format 510 that delineates a region entirely can provide an enclosed region530. In addition, however, as noted above, linear embossing patterns 500 that include linear embossing elements 510 that only partially delineate a region can provide at least partially enclosed regions 530 which are also within the scope of the invention.

Finally, linear embossing pattern 500 may include only linear embossing elements that do not surround or in any way delimit regions and thus provide no enclosed or at least partially enclosed regions 530, as described herein and shown in Figure 8.

Figure 9 shows an example of a hitch de-embossing pattern or what it would look like if the second embossing pattern 500 of Figure 8 including linear embossing elements 510 were or engaged with the first distinct embossing element pattern 410, as shown in a only plan. As shown, the linear embossing elements 510 of the second embossing pattern 500 are adjacent and arranged between the distinct embossing elements 410 of the first embossing pattern 400. In this specific configuration, each distinct embossing element 410 is adjacent to a linear embossing element 510. In addition, In this specific embodiment, all linear embossing elements 510 (in this case in a generally square format) are separated from each other by at least one distinct embossing element 410. In addition, as shown in Figure 9, linear embossing elements 510 provide closed regions 530 within the boundaries. linear embossing elements 510. In the specific embodiment shown, when the linear embossing pattern 500 is engaged with a separate embossing pattern 400, the enclosed regions 530 include distinct embossing elements 410. Although in Figure 9 it is shown that all enclosed region 530 includes but one. distinct embossing element 410 when embossing patterns 400 and 500 are engaged, such that they are considered where distinct embossing elements 410 are not arranged in any enclosed or partially enclosed region 530 or are arranged only in an enclosed or partially enclosed region or are arranged in some but not all enclosed or enclosed regions. partially closed 530.

It has been found that interposing linear debonding elements, such as those shown in Figure 8, between distinct embossing elements, such as those shown in Figure 7, can provide unique benefits to the embossing process and the embossed blanket. For example, as compared to deep-coarse embossing plates or rollers, married including only distinct embossing elements, the matching of linear embossing elements with distinct embossing elements may reduce the likelihood that the web will be damaged or cut embossing. In addition, the use of such a device can increase the reliability of the embossing process, thereby reducing downtime and cost of providing the final product. Still further, with respect to the matting, the use of the apparatus 10 of the present invention may provide the mat with improved softness and smoothness properties. Still further, the apparatus 10 of the present invention may be used to produce a blanket product that is more aesthetically pleasing than a typical apparatus and method that includes only distinct embossing element patterns or even distinct linearese elements which are not interposed as the standards are shown, for example. In addition, the present apparatus and method for embossing a blanket may provide a side embossed blanket. That is, the blanket has very different appearance and feel characteristics on the opposite surfaces of the blanket. In certain embodiments, alaterality may be convenient.

Figures 10A to C are just a few examples of alternative linear embossing elements 610, 620 and 630 having different shapes. In each case, the linear deformation elements 610, 620 and 630 have a length L and a width W, measured as set forth herein and shown in the Figures. In each case, the linear embossing element has a longitudinal centerline 650 extending the long length of the embossing element. As shown, the length L of each embossing element is derived by measuring the embossing length along the longitudinal centerline 6509 from one end of the embossing element to the opposite end of the embossing element. Width W is measured generally perpendicular to the longitudinal axis 650. As noted above, for the purpose of determining the length to width ratio of the linear element, the width W is measured at the point where the embossing element is the widest or the width value will be the largest. .

Figure 11 shows a plan view of an exemplary embossing pattern including a plurality of linear embossing elements 700 and a plurality of distinct embossing elements 710. In the specific pattern shown, linear embossing elements 700 are non-uniform in width and provide spaces 720 into the which distinct embossing elements can be arranged or engaged. In the example shown, the linear embossing elements 700 have a first width 730 and a second width 740. The first width 730 is smaller than the second width 740. Therefore, in the shown configuration, the first smaller widths 730 of the linear embossing elements 700 provide the spaces 720 n— which distinct embossing elements 710 are arranged or engaged. (As noted above, the embossed blanket using apparatus 10 of the present invention may include embossings that are of the same general shape, size and pattern as embossing elements embossing the blanket. Of this, an embossed blanket having embossings of shape, size and configuration in a pattern. similar to that described here with respect to embossing elements is considered.)

The embossing elements 710 and 720 shown in Figure 11 could be configured such that the linear embossing elements 700 and the distinct embossing elements 710 are arranged in a single embossing member. Alternatively, at least one of the linear embossing elements 700 could be arranged in a first embossing element and at least one of the distinct embossing elements could be arranged in such a way that they engage when embossing elements are joined to emboss a web. In still another embodiment, all linear embossing elements 700 may be arranged on a first embossing member and all distinct embossing elements 710 may be disposed on a second embossing member.

Figure 12 is a plan view of a standard 800 linear embossing element 805. The linear embossing elements 805 are generally in the shape of a square outline and are of non-uniform width. As shown, linear embossing elements 805 have a first width 810, a second width 820 and a third width 830. In the specific embodiment shown in Figure 12, the first width 810 is greater than the second width 820 and the third width 830 is greater than the first width. width 810 and the second width 820. Also, as shown, linear embossing elements 805, although not uniform in width, have a regular pattern of change in width, but such a regular pattern is not required for any specific embodiment.

Figure 13 shows an example of the engagement of two embossing patterns, or as it would look if the embossing pattern 800 of Figure 12 including linear embossing elements 805 were disposed on or engaged with a distinct embossing element pattern 905 similar to that of the standard 400 of FIG. 7. (Pattern 900 of Figure 13 and Pattern 400 of Figure 7 are not to be of the same scale, but are simply representative of generally similar patterns of distinct embossing elements.) As shown, linear embossing elements 805 of embossing pattern 800 are adjacent between the separate embossing elements 905 and the embossing standard 900. In this specific configuration, each distinct embossing element 905 is adjacent to a linear embossing element 805. In addition, in this embodiment, all linear embossing elements 805 (in this case format) are specified. square) are separated from each other by at least one gofrage element Also, as shown in Figure 13, linear embossing elements 805 provide narrow regions 840 within the boundaries of linear embossing elements 805. In the specific embodiment shown, when linear embossing pattern 800 is engaged with the distinct embossing pattern 900, the regions 840 include discrete embossing elements 905. Although in Figure 13 it is shown that every enclosed region 840 includes at least one distinct embossing element 905 when the embossing patterns 800 and 900 are engaged, where discrete embossing elements 905 are not arranged in any enclosed region. or partially enclosed 840 or are arranged only in an enclosed or partially enclosed region or are arranged in some but not all enclosed or partially enclosed regions 840. Figure 13 also shows a embodiment of the present invention wherein, when engaged, the non-uniform width of the members 805 linear embossing provides a unique embossing pattern with the distinct embossing elements 905, similar to that shown in Figure 11. In particular, at least some of the distinct debarking elements 905 are located in spaces 850 provided by the regions of the narrow-pitched linear elements 805, which generally correspond to the portions of the linear embossing elements 805 having the second width 820. In the embodiment shown, the linear embossing elements 805 they are aligned such that the linear embossing elements 805 that are closest to each other have corresponding regions of reduced width860. These corresponding narrow-width regions 860 provide at least some of the spaces 850 in which the distinct embossing elements 905 may be arranged or engaged. The provision of such non-uniform linear embossing elements 805 in a pattern where the linear embossing elements 805 are aligned such that the linear embossing elements 805 which are closest to each other have corresponding regions of reduced width 860 and provide at least some From the spaces 850n — which distinct embossing elements 905 may be arranged or engaged, it may be advantageous for the method of the present invention as well as the blanket which is embossed by the method. Such advantages may include, but are not limited to, increased softness, higher line efficiency, reduced web breaks, and fewer holes in the web created by the embossing process.

Another aspect of the present invention which may provide advantages over other embossing apparatus and methods relates to the total embossing surface area of the embossing elements relative to the overall surface area (or distal end) of the embossing members as well as the relationship between the embossing area. deburring surface of linear embossing elements and distinct deburring elements. Figure 14 shows a combined embossing pattern 875 including linear embossing pattern 900 including linear embossing elements 910 and distinct embossing pattern 950 including distinct embossing elements 960. As with Figures 9 and 13, Figure 14 shows both the linear embossing pattern 900 as the distinct embossing pattern 950 as they would appear to be engaged but shown in a single plane. The distal end or embossing surface 920 and 970 of the linear embossing elements 910 and distinct embossing elements 960, respectively, are shown. (As used herein, the term "distal end" refers to the surface of the embossing element that is located away from the surface of the embossing. embossing member generally contacting the embossing mat In most cases the distal end will be generally flat but could have a slight bend or taper, so for purposes of the present invention the distal end included surface of the embossing element which is raised from the surface of the embossing member and generally parallel to the surface of the embossing member, including deviations from up to 45 degrees parallel.) The combined embossing pattern 875 includes a repeating pattern on all linear embossing elements 910 as distinct embossing elements. 960. A single projected planar view of the pattern d and repeat combination embossing 875 is shown and labeled 975. In that specific embodiment, the single embossing pattern unit 975 is repeated as shown to form the combined embossing pattern 875.

(Of course, different repeating units can be used and one shown in Figure 14 is just a limiting example of a combined embossing pattern that could be used.)

In certain embodiments of the present invention, it may be convenient to design the distinct embossing elements 960 of the distinct embossing pattern 950 such that they are arranged in a first single pattern unit 972. The first single pattern unit 972 includes the distal end portions 970 of the distinct deburring elements 960 which are located in a single standard embossing unit 975. It may be convenient that the total distal end area 970 of the distinct embossing elements 960 in any unit specific embossing single pattern, 975, (or single pattern first unit 972) is a certain area or less. For example, it may be convenient for the total area of the distal ends 970 of the discrete embossing elements 960 in a first single pattern unit 972 to be less than about 5.0 cm2, less than about 3.5 cm2, less than about 3 .0 cm2 or less than about 2.5 cm2.

In addition, while the flat projected area of any specific single embossing pattern unit may be of any value, in some embodiments, it may be convenient for the flat projected area to be of value or within a range of values. (The flat projected area of a 975 single-pattern embossing unit can be obtained from an impression of the embossing member or the drawing set used for embossing the embossing member.) In certain embodiments, it may be convenient that the flat projected area of the embossing unit 975 single embossing standard is about 25 cm2. In other exemplary embodiments, the flat projected area of a single 975 embossing pattern unit is larger than about 5 cm2, greater than about 10 cm2, larger than about 20 cm2, greater than about 30 cm2, larger than approximately 50 cm2, greater than about 100 cm2 or any area suitable for the specific desired design.

It may also be convenient to design the distinct embossing elements 960 such that the total area of the distal end area 970 of all distinct embossing elements 960 in a first unit of single pattern 972 is less than about 25%, less than about 20%. %, less than about 15%, less than about 13%, less than about 12.5%, less than about 10%, less than about 5%, or even less than about 2, 5% of the total flat projected area of the 975 single-pattern embossing unit. (If the first 972 single-pattern unit is repeated over the entire surface of the embossing member, the percentages of total exposed area above a first single pattern unit would also correspond. generically to the total area of the distal ends 970 of the distinct embossing elements 960 in every distinct embossing pattern 950.) ·

To calculate a total area value for the distal ends of any specific type of embossing element or embossing elements in a first single pattern unit 972, the single embossing pattern unit 975 is first identified. Then, the individual area of each of the distal ends, as defined herein, of each of the relevant embossing elements in the single embossing standard unit 975 is measured. The area value is the sum of the individual measured areas. (Only the portion or portions of a embossing element that is part of the distal end, as defined herein, and is part of the single embossing pattern unit, is included in the total area.) An appropriate method for obtaining area measurements is by use of embossing software. computer aided design, such as AUTOCAD 2004. To obtain the individual area of the distal end of any specific embossing element, the distal end of the embossing element is drawn to scale. The Program Area function can then be used to calculate the individual area of the distal end of that particular embossing element. The individual areas of the distal ends of any other embossing elements in the single pattern embossing unit 975 can then be measured in the same way and the program Sum function can be used to add the individual areas to provide the total area value. AUTOCAD 2004 can also be used to measure the flat projected area of the 975 single pattern embossing unit.

In certain embodiments of the present invention, it may be convenient to design the linear embossing elements 910 of the linear embossing pattern 900 so that they are arranged in a second simple standard unit974. The second simple standard unit includes the distal end portions 920 of the linear embossing elements 910, which are located in a single standard unit of the particular embossing pattern 975. It may be convenient for the total distal end area 920 of the linear embossing elements 910 to be in any single standard unit 975. particular embossing pattern (or second single standard unit 974) is of a given area or smaller. For example, it may be convenient that the total area of distal ends 920 of the linear embossing elements 910 in a second simple standard unit 974 be less than about 10 cm2, less than about 7.5 cm2, less than about 5.0 cm2, less than about 3.0 cm2 or less than 2.5 cm2. It may also be convenient to design the linear embossing elements 910 so that the total distal end area 920 of all linear embossing elements 910 in a second simple standard unit 974 is less than about 50%, less than about 40%, less than about 30%, less than about 25%, less than about 20%, less than about 15% or less than about 13%, less than about 10%, less than about 5%, or even less than about 2%. , 5% of the total flat projected area of the single standard unit of the embossing pattern 97 5 (as noted above with respect to the distinct embossing elements 960, if the second single standard unit 974 is repeated over the entire surface of the embossing member, the total area percentages given above with respect to the second single standard unit 974 would also correspond generally to the total area of the distal ends 920 of the linear embossing elements 910 across the entire linear embossing pattern 900).

It may also be convenient to configure the linear embossing elements 910 of the linear embossing pattern 900 and the separate embossing elements 960 of the separate embossing pattern 950 such that the ratio of the sum of the distal end area 920 of the linear embossing elements 910 to the sum from the area of the distal ends 970 of the discrete embossing elements 960 to any single standard unit of the particular embossing pattern 975 is less than about 3: 1, less than about 2: 1 or about 1: 1. It is believed that the selection of a given area for the distal ends of the embossing elements, the total area of the embossing elements, the percentage of the total flat projected area of the single pattern embossing pattern unit covered by the distal ends of the distinct / linear and embossing embossing elements. The ratio of the sum of the distal ends of the distinct embossing elements to the total area of the linear embossing elements can provide advantages to the embossing process, such as increased softness, increased line efficiency, reduced tear breaks, and smaller holes in the blanket created by the defrosting process and better overall appearance of the resulting blanket.

As mentioned above, the process of the present invention for producing a deep-embossing embossed mat includes the steps of providing a first embossing member such as a roll, or similar plate, including at least a first embossing element, such as a distinct embossing element. A second embossing member is also provided which includes at least one second embossing element as a linear embossing element. The first embossing member and the second embossing member are arranged adjacent to each other such that the first embossing member and the second embossing member are capable of interlocking. In the situation where at least one of the debossing members is a roll, a choke is formed between the orol and the other embossing member. A blanket is passed through the choke and is embossed as it passes through the choke (for example, the process shown in Figure 2). If the embossing platforms are both plates or the like where no strangulation forms, and the blanket is passed between the embossing members and then the plates, for example, are directed against each other such that the first second embossing elements 50 and 60 are engage. The plates are then disengaged and the thick part of the blanket is removed between the plates. In either case, the blanket is subjected to deep nesting embossing. Further, the particular pattern of the first embossing elements 50e of the second embossing elements 60 is chosen to match the resulting mat product 100 with the particular aesthetic and / or desired physical properties.

In some embodiments of the present invention, it may be convenient to orient the first embossing elements 50 and the second embossing elements 60 into a particular mode, because they refer to the thin product of the mat 100. That is, it may be convenient to have the layer or layers of the blanket 100 passing through the deburring apparatus 10 such that the first embossing elements 50 deform the blanket 100 towards the outer surface 330 of the blanket 100. (The outer surface 330 of the blanket is the surface that typically appears outside when the product is in a package or already stored for use, which typically corresponds to the surface of the product that the consumer first sees and touches during normal use. Exemplary Representations of Inner Surface 340 Damage 100 and the outer surface 330 of the blanket 100 are shown in Figure 6). More particularly, in some embodiments, it may be convenient for the deburring apparatus 10 and the method to be configured such that the first embossing elements 50 are distinct debarking elements 410, for example those shown in Figure 7, and that they are oriented such that deform the mat 100 towards the inner surface 340 of the mat 100 and form separate embossing 310. In such or other embodiments, it may be convenient for the second embossing elements 60 to include linear embossing elements, such as, for example, embossing elements 510 shown in Figure. 8. Thus, the embossing apparatus 10 may be configured such that the linear embossing elements 510 deform the web 100 towards the outer surface 330 of the web 100 to form linear embossings 315. In such configurations, it has been found that 100 embossing is allowed to form. Dry may appear softer and may, of course, be softer to the touch by the user. (Although not wishing to be bound by theory, this is believed to be due to the reduced number of separate embossings 310 extending toward the outer surface 330 of the blanket 100.

In embodiments such as those described above, where the distinct embossing pattern formed from the distinct embossing elements 410 is directed inwardly from the inner surface 340 of the blanket 100 and the linear embossing pattern formed from the linear embossing elements 510 is directed outwardly, in the direction of the surface. outer layer 330 of the mat 100, a mat with especially convenient aesthetic and physical characteristics can be produced. In such embodiments, inward-facing embossing may be produced to stand as a cushioning pattern, while the outwardly extending linear embossing pattern may look and / or have padded regions between the cushioning pattern. This is an improvement over the prior art, where all or all embossing was distinct or where embossing, distinct or otherwise, all had the same direction (typically inward) relative to the surfaces of the resulting blanket.

The resulting 100 embossed blanket will typically have embossing with an average embossing height of at least 650 μm. Other embodiments may have embossing with embossing heights greater than 1000 μπι, greater than about 1250μm, greater than about 1450 μm, at least about 1550 μm, at least about 1800 μm, at least about 2000 μm, at least about 3000 μm , at least about 4000 μm, between about 650 μπι and about 4000 6m or any individual number within this range. The average formwork height is measured by the Formwork Height Test Method using a GFMMikroCAD optical profiling instrument as described in the paragraph below.

As noted, the apparatus 10 of the present invention may act on any deformable material. However, the device 10 is most commonly used for forming mat-like structures or products that are generally flat and having significantly longer width and width dimensions than the mat thickness. product. Often, it is advantageous to use such an apparatus 10 on films, nonwoven, matted materials, sheets, fibrous structures and the like. A suitable type of blanket for use with the apparatus 10 of the present invention is a paper blanket (as used herein, the term "paper blanket" refers to blankets including at least some cellulosic fibers. However, suitable paper blankets are considered to be suitable. for use with the apparatus 10 of the present invention may also include fibers including synthetic materials, natural fibers other than those including cellulose and / or hand made fibers, including natural materials). Some paper blankets are suitable for use as paper towels. As used herein the term "hygienic paper product - paper towel" refers to products comprising a toilet paper blanket or paper towel including, without limitation, conventional or felted conventional wet-pressed toilet paper; blankets of dense torn paper tissue; and large volumes of uncompressed toilet paper. Some non-limiting examples of toilet paper / paper towels include paper towels, tissues, toilet paper, and similar table napkins.

In some embodiments of the present invention the method includes providing one or more layers of paper with a non-embossed wet tear resistance. The paper web is embossed resulting in a web with a series of deburring with an average embossing height of at least 650 μm. In some embodiments, it may be convenient for the resulting mat to have a wet breaking strength greater than 300 g. In addition, it may be convenient for the resulting mat to have a wet break resistance greater than about 60%, greater than about 70%, greater than about 75% greater than about 80%, greater than about 85%, greater than about 90%, or greater than about 92%, of the non-embossed wet burst resistance. In such embodiments, the paper layer or layers produced to be the substrate of the deep nesting embossed paper product may be any type of fibrous structures described herein, such as, for example, the paper is a towel / toilet paper product. Resistance to wet breakage when non-embossed of the strata to be used is measured according to the wet breakage resistance test method described below. When more than one stratum of paper is embossed, wet breakage resistance is measured on a sampled sample of individual layers placed together, glued face-to-face, to the tester.

Papermaking fibers useful in the present invention include known cellulosic fibers as wood pulp fibers. Useful wood pulps include chemical pulps such as Kraft pulps, sulfite sulfate, as well as mechanical pulps including, for example, ground wood, thermomechanical pulp and chemically modified thermomechanical pulp. Chemical pulps, however, may be preferred in certain embodiments, as they may impart a great tactile sensation of softness to the toilet paper sheets produced therefrom.

Both pulp derived from deciduous trees (also called "hardwood" later in this document) and those from coniferous trees (also referred to as "softwood" later in this document) can be used. Hardwood and softwood fibers may be blended or alternatively may be layered to form a stratified mat. U.S. Patent Nos. 4,300,981 and 3,994,771 disclose the formation of hardwood and wood fiber layers soft. Also applicable to the present invention are fibers derived from recycled paper, which may contain any or all of the above categories, as well as other non-fibrous materials such as fillers and adhesives used to facilitate the manufacture of the original paper. In addition to the above, fibers and / or filaments made of polymers, specifically hydroxyl polymers, may be used in the present invention. Some non-limiting examples of suitable hydroxyl polymers include polyvinyl alcohol, starch, starch derivatives, chitosan, chitosan derivatives, cellulose derivatives, gums, arabinans, galactans, and combinations thereof.

The papermaking fibers used for the present invention usually include wood pulp derived fibers. Other natural pulp fibers, such as cotton down, bagasse, wool fibers, silk fibers, etc. may be used and are intended to be included within the scope of this invention. Synthetic fibers such as rayon fibers, polyethylene and polypropylene can also be used in combination with natural cellulosic fibers. An example of polyethylene fiber that can be used is Pulpex®, available from Hercules, Inc. (Wilmington, DE, USA).

Representative examples of other paper substrates can be found in Patent No. 4,629,643 issued to Curro et al., December 16, 1986, U.S. Serial Patent 4,609,518 issued to Curro etal., September 2, 1986; U.S. Patent No. 4,603,069 issued to Haq et al. On July 29, 1986; U.S. Patent Copending Publications2004 / 0154768 A1 published to Trokhan et al. On August 12, 2004; 2004/0154767 A1 issued to Trokhan et al. On August 12, 2004; 2003/0021952 A1 issued to Zinket al. On January 30, 2003; and 2003/0028165 Granted to Curro et al. on February 6, 2003.

The paper product substrate may comprise any paper product known in the industry. The modality of such substrates may be in accordance with U.S. Serial Patents 4,191,609 issued March 4, 1980 to Trokhan; 4,300,981 issued to Carstens on November 17, 1981; 4,514,345 issued to Johnson et al. On April 30, 1985; 4,528,239 issued to Trokhan on July 9, 1985; 4,529,480 issued to Trokhan on July 16, 1985; 4,637,859 issued to Trokhan on January 20, 1987; 5,245,025 issued to Trokhan et al. On Dec. 14, 1993; 5,275,700 issued to Trokhan on January 4, 1994; 5,328,565 issued to Rasch et al. On July 12, 1994; 5,334,289 issued to Trokhan et al. On August 2, 1994; No. 5,364,504 issued to Smurkowski etal. On November 15, 1995; 5,527,428 issued to Torkhan et al. On June 18, 1996; 5,556,509 issued to Trokhan et al. On September 17, 1996; 5,628,876 issued to Ayers et al. On May 13, 1997; 5,629,052 issued to Trokhan et al. On May 13, 1997; 5,637,194 issued to Ampulski et al. On June 10, 1997; 5,411,636 issued to Hermans et al., May 2, 1995; 6,017,417 issued to Wendt et al. On January 25, 2000; 5,746,887 issued to Wendt et al. On May 5, 1998; 5,672,248 issued to Wendt et al. On December 30, 1997; and U.S. Patent Application 2004 / 0192136A1 published in the name of Gusky et al., on September 30, 2004.

Paper substrates can be manufactured via a wet deposited papermaking process where the resulting mat is air dried or conventionally dried. Optionally, the substrate may be shortened beforehand by curling, wet microcontracting or by any other means. Wet curling and / or self-contraction are disclosed in patents issued to the same Depositor of this application under U.S. Serial No. 6,048,938, issued to Neal et al., On April 11, 2000; 5,942,085 issued to Neal et al. On August 24, 1999; 5,865,950 issued to Vinson et al. On February 2, 1999; 4,440,597 issued to Wells et al., April 3, 1984; 4,191,756 issued to Sawdai 4, 1980; and 6,187,138 issued to Neal et al. 13 February 2001.

Conventionally compressed tissue paper and methods for making such paper are, as described, for example, in US Patent No. 6,547,928 issued to Barnholtz et al., April 15, 2003. A suitable hygienic paper is standard densified toilet paper, which is CHARACTERIZED for having a relatively low fiber density field with a relatively high number, and a set of relatively high fiber density densified zones. The high volume field is alternatively CHARACTERIZED as a paddy field. Densified zones are alternatively referred to as overhang regions. Densified zones may be either distinctly spaced, or interconnected, wholly or partially, within the high volume camp. Processes for producing standard densified hygienic paper webs are disclosed in U.S. Patents. 3,301,746 issued to Sanford and Sisson on January 31, 1967; 3,473,576, issued to Amneus on October 21, 1969; 3,573,164 issued to Friedberg, et al. On March 30, 1971; 3,821,068 issued to Salvucci, Jr. et al. On May 21, 1974; 3,974,025 issued to Ayers on August 10, 1976; 4,191,609 issued to ... on December 4, 1980; 4,239,065 issued to Trokhan on December 16, 1980 and 4,528,239 issued to Trokhan on July 9, 1985 and 4,637,859 issued to Trokhan on January 20, 1987.

Uncompressed, non-densified standard toilet paper structures are also encompassed within the scope of the present invention and are described in U.S. Pat. No. 3,812,000 issued to Joseph L. Salvucci, Jr. and Peter N. Yiannos on May 21, 1974, and US Patent 4,208,459 issued to Henry E. Becker, Albert L. McConnell, and Richard Schutte on June 17, 1980 .

Paper other than crepe can also be subjected to the apparatus and method of the present invention. Appropriate techniques for producing unruffled toilet paper are taught, for example, in U.S. Patent Nos. 6,017,417 issued to Wendt et al. On January 25, 2000; 5,748,687 issued to Wendt et al. On May 5, 1998; 5,672,248 issued to Wendt et al. on September 30, 1997; 5,888,347 issued to Engel et al. On March 30, 1999; 5,667,636 issued to Engel et al. On September 16, 1997; 5,607,551 issued to Farrington et al. On March 4, 1997 and 5,656,132 issued to Farrington et al. On August 12, 1997.

The towel / toilet paper substrates of the present invention may alternatively be manufactured via an air exposure production process. Typical air exposure processes include one or more forming chambers that are placed over a potholed surface such as a forming screen. For example, fibrous materials and particulate materials are introduced into the forming chambers, and a vacuum source is employed to drag an air stream through the forming surface. The air stream deposits the fibers and particulate material on the shifting forming surface. Once the fibers are deposited on the forming surface, an air-exposed blanket substrate is formed. Once the blanket leaves the forming chambers, the blanket is passed through one or more compaction devices which increases the density and resistance of the blanket. The density of the mat may be increased from about 0.05 g / cm3 to about 0.5 g / cm3. After compaction, one or both sides of the mat may optionally be sprayed with a glue material such as latex, or other known water-soluble binders, to add wet and dry resistance. If a binding agent is applied, a mat is passed, typically through a drying apparatus. An example of such a process for manufacturing air-exposed paper substrates is seen in U.S. Patent Application No. 2004.0192136A1, filed in the name of Gusky et al., Published September 30, 2004.

The apparatus and method of the present invention is not limited to any particular type of papermaking or conversion equipment and may be operated at any suitable line speed. Some exemplary papermaking and converting equipment are identified herein. Additionally, without being limited to any particular inline speed, however, typical inline conversion speeds would generally range from about 300 to about 700 m / min.

Other optional equipment may be employed and / or processes may be performed on the blanket during manufacture or after manufacture, as appropriate. Such processes may be carried out before or after the embossing method of the present invention, as applicable. For example, in some embodiments, it may be convenient to print on the blanket. It may also be convenient to record the printout to the embossed pattern.

Exemplary methods for registration of the de-molding form are described in more detail in US Patent Application Publication No. 2004/0258887 Al published December 23, 2004 and 2004/0261639 al published December 30, 2004. It may also be convenient to provide heat, moisture or vapor to the blanket before it is embossed. Exemplary suitable apparatus and methods for providing vapor to a embossing blanket are described in U.S. nos. No. 4,207,143 issued to Glomb et al. On June 10, 1980, 4,994,144 issued to Smith et al on February 19, 1991; 6,074,525, granted to Richards on June 13, 2000 and 6,077,590, granted to Archer on June 20, 2000. However, any suitable apparatus and / or method for providing heat, moisture or steam to the blanket may be used, including the use of steam bars, airfoils, sprayers, steam chambers or any combination thereof.

In addition, for paper webs, optional materials may be added to the aqueous paper-making assortment or embryonic blanket in order to impart other desirable product characteristics or to improve the papermaking process. Examples of such materials may include softening agents, moisture resistance agents, surfactants, fillers, and other known additives or combinations thereof. Similarly, for non-paper webs, optional ingredients, coatings or processes may be employed to provide the mat with any desired particular characteristics. and / or alter the physical or chemical characteristics of the basic blanket.

An example of an embossed blanket product can be seen in Figure 6. The 100 embossed blanket product comprises one or more layers, wherein at least one of the layers comprises a series of separate embossing 310 and a series of other linear embossing 315. (Generally, embossing have a shape similar to the embossing elements used to form embossing, so for purposes of this patent the embossing element shapes and sizes described herein may also be used for the purpose of describing suitable embossing. The shape of the embossing may not correspond exactly to the shape of any particular embossing element or embossing pattern and therefore embossing of different shapes and sizes than those described herein with respect to embossing elements). The stratum or strata which is embossed, do so in a deep nesting embossing process, such that the embossings have a embossing height of at least 650 μπι, at least about 1000 μπι, at least about 1250μπι, at least about 1450 μπι, at least about 1550 μπι, at least about 1800 μπι, between about 650 μπι and about 1800 μπι, at least about 2000 μπι, at least about 3000 μπι, at least about 4000 μπι, between about 650 μπι and about 4000 μπι, or any individual number in this range. The defrosting height 320 of the 100 embossed product is measured by the Embossing Height Test method described below.

The matting product of the present invention will have a non-embossed wet-breaking resistance and a wet-breaking resistance of the resulting or embossed mat. Typically, for paper products, the resulting blanket product 100 made by the process of the present invention will have a wet breakage resistance greater than about 300 g, although there is no minimum limit on wet breakage resistance. It is quite convenient for the resulting mat product 100 to have a wet-breaking resistance greater than about 60%, greater than about 65%, greater than about 70%, greater than about 75%, greater than about 80%, greater than about 85%, greater than about 90%, or greater than about 92% of the resistance to non-embossed wet burst. Although not required in all modalities, two of the factors that may contribute to increased wet break resistance efficiency (wet break resistance of the embossed mat as a percentage of wet break resistance of the un embossed mat) include slow addition to the mat before embossing and the radius of curvature of the transition regions of embossing elements, both of which are described herein. Thus, employing essentially the same apparatus and method for stamping embossing, the addition of steam, and / or the use of stamping elements, with curved transition regions can provide a final product with a wet breaking strength and / or a resistance efficiency. wet breaking with a lower lower limit than in the case of a blanket not subjected to one or both of the steam and / or embossing elements with curved transition regions.

The blanket product of the present invention may be converted for sale or use in any desired shape. For example, the blanket may be rolled, folded, stacked, punched and / or cut into individual sheets of any desired size.

Example 1

A useful fibrous structure for acquisition of the embossed paper product is the air dry differential density (TAD) structure described in U.S. Patent No. 4,528,239. This structure can be formed by the process described below:

A Fourdrinier air drying paper making machine is employed in the practice of this invention. A papermaking fiber slurry is pumped into the front case to a consistency of about 0.15%. The sludge consists of about 55% KraftNorthern Softwood fibers, about 30% of undefined Eucalyptus fibers, and about 15% of pulp recycle waste. The fiber slurry contains a cationic polyamine-epichlorohydrin wet-breakable resin at a concentration of about 10.0 kg / metric ton of dry fiber and carboxymethyl cellulose at a concentration of about 3.5 kg / metric ton of dry fiber.

The removal of water occurs through the display screen with the help of vacuum boxes. The screen has the following configuration: 41.7 filaments / cm in machine direction and 42.5 in transverse direction, as available from Asten Johnson known as a "786 screen".

The embryonic wet blanket is transferred from the Fooddrinier mesh, at a fiber consistency about 22% at the transfer point, to an air-dried (TAD) transport fabric. The screen speed is about 660 meters per minute. The speed of the transport fabric is about 635 meters per minute. Since the speed of the canvas is about 4% higher than that of the transport fabric, the wet shrinkage of the blanket occurs at the point of transfer. Therefore, the size reduction of the damp blanket is about 4%. The sheet side of the transporting fabric consists of a continuous shaped photopolymer resin net, the pattern containing about 37 deflection ducts per centimeter (or 90 ducts per inch). The deflection conduits are arranged in an amorphous configuration, and the polymer network covers about 25% of the surface area of the transport tissue. The polymer resin is supported by and attached to a woven support element having 27.6 filaments in the machine direction and 13.8 filaments in the transverse direction per centimeter. The photopolymer web rises about 0.43 mm above the support element. .

The consistency of the blanket is about 65% after the action of TAD dryers operating at about 254 ° C prior to transfer to the Yankee dryer. An aqueous solution of masking tape and polyvinyl alcohol is applied to the Yankee surface by spray applicators at a speed of about 0.66 kg / metric ton production. Yankee Dryer is operated at a speed of about 635 meters per minute. The fiber consistency is increased to an estimated 95.5% before curling by a scraper blade. The scraper blade has a bevel angle of about 33 degrees, and is positioned relative to the Yankee dryer to provide an impact angle of about 87 degrees. The Yankee dryer operates at about 157 ° C, and the Yankee hoods are operated at about 120 ° C.

The dry, frayed blanket is passed between calender rollers and wrapped in a coil operating at 606 meters per minute, so that there is about 9% reduction in the size of the thickened blanket, about 4% by wet microcontraction, and a further 5%. by dry curling. The resulting paper has a basis weight of 23 grams per square meter (g / m2).

The paper described above is then subjected to the deep nesting embossing process of this invention. Two embossing cylinders are engraved complementary to the nesting embossing elements shown in Figures 7 to 9. The cylinders are mounted on the apparatus with their respective axes generally parallel to each other. The distinct embossing elements have a cone-shaped shape, with a front diameter (top or distal - that is, away from the roll from which they project) - about 2.79 mm and a lower diameter (bottom or proximal - that is, closest to the surface of the roll from which they protrude) about 4.12 mm. The linear elements have a similar width to that of the distinct embossing elements, about 2.79 mm. The height of the embossing elements on each roll is about 3.81 mm. The radius of curvature of the transition region of the embossing element is about 0.76mm. The flat projected area of each standard single unit of embossing pattern is about 25 cm2. Adjustment of the nested rollers is about 3.56 mm and the paper described above is introduced through the adjustment range at a speed between 300 and 400 m / min. The resulting paper has a embossing height greater than about 1450 æm, a wet break resistance of the finished product greater than about 70% of its unbroken wet break resistance.

EXAMPLE 2

In another embodiment the embossed paper products, two separate paper layers are produced from the papermaking process of Example 1. The two layers are then combined and embossed together by the deep nesting embossing process of Example 1. The resulting paper has a height of embossing greater than about 1450 μτη, a wet-breaking strength of the finished product greater than about 70% of its resistance to un-embossed wet-breaking.

EXAMPLE 3

In another embodiment, separate paper layers are produced from the papermaking process of Example 1. Two of the layers are embossed by the deep nesting process of Example 1. The three toilet paper layers are then combined into a standard converting process so as to that the two embossed layers are the respective outer layers, and the unembossed layer is the inner layer of the product. The resulting paper has a embossing height greater than about 1450 μm, a wet breakout resistance of the finished product greater than about 70% of its unfolding wet breakout resistance.

EXAMPLE 4 In another embodiment, the paper described in example 1 is subjected to a deep nesting process as described in Example 1. Distinct embossing elements have a frusto-conical shape, with a front or distal diameter, ie, away from the roll of which they about 2.26 mm and a smaller diameter (bottom or proximal - that is, the closest to the surface of the roll from which they protrude) about 4.12 mm. The linear elements have a width similar to those of distinct embossing elements, about 2.26 mm. The height of the embossing elements on each roll is about 3.81 mm. The radius of curvature of the transition region of the embossing element is about 0.76 mm. The flat projected area of each unique standard unit of the embossing pattern is about 17 cm2. Adjustment of the nested rollers is made about 3.1 mm and the paper described above is fed through the adjustment range at a speed of between 300 and 400 m / min. The resulting paper has a shredding height greater than about 1450 μιτι, a wet breakage resistance of the finished product greater than about 70% of its unembossed wet breakage resistance.

EXAMPLE 5

In another embodiment, the paper described in Example 1 is subjected to a deep-aligning embossing process as described in Example 1. The distinct embossing elements have a frusto-conical shape with a front diameter (top or distal, i.e. distant from the roll). about 2.79 mm and a smaller diameter (bottom or proximal - ie, closest to the surface of the roll from which they protrude) about 4.12 mm. The linear elements have a similar width to that of the distinct embossing elements, about 2.79 mm. The height of the embossing elements on each roll is about 3.81 mm. The radius of curvature of the transition region of the embossing element is about 0.76mm. The flat projected area of CAD standard unit singular embossing pattern is about 25 cm2. Adjustment of the nested rollers is about 3.1 mm and the paper described above is introduced through the throttling throttling at a speed of between 300 and 400 m / min.

However, before introducing the paper through the choke, steam is directed onto a paper surface. The paper temperature at the embossing point is about 36 ° C. The resulting paper has a embossing height greater than about 1450 μια, a wet breakout resistance of the finished product greater than about 85% of its unbroken wet breakout resistance.

EXAMPLE 6

An example of an air-dried, differential density structure as described in U.S. Patent No. 4,528,239 may be formed by the following process.

The TAD carrier fabric of Example 1 is replaced by a carrier fabric consisting of 88.6 percent biaxially misaligned deflection conduits with a resin height of about 0.305 mm. Opapel is subjected to the embossing process of Example I, and the resulting opapel has a greater embossing height of about 1.4 50 μπ \ and a wet break resistance of the finished product greater than about 70% of its non-embossed wet break resistance.

Example 7

An alternative embodiment is a paper structure with a greater 5% wet microcontraction in combination with any known air-drying process. Wet microcontraction is described in U.S. Patent No. 4,440,597. An example of this embodiment may be produced by the following process.

The screen speed is increased to about 706 meters per minute. The speed of the transport tissue is about 635 millimeters per minute. The screen speed is 10% higher compared to the TAD transport fabric, so the wet size reduction of the mat is 10%. The TAD carrier fabric of Example 1 is replaced by a carrier fabric having a 5-shed web with 14.2 machine direction filaments and 12.6 transverse direction filaments per centimeter. The speed of Yankee equipment is about 635 meters per minute, and the coil speed is about 572 meters per minute. The blanket is shrunk by 10% by wet microcontraction, and a further 10% by dry curling. The pre-embossing paper has a basis weight of about 33g / m2. This paper is further subjected to the embossing process of Example 1, and the resulting paper has an embossing height greater than about 1,450 μιτι and a wet break resistance of the finished product greater than about 70% of its non-wet wet strength. embossed.TEST METHODS

Embossing Height Test Method

The height of the embossing is measured using a compact Optical3D Measuring System MIkroCAD for paper-measuring instrument (the "GFM MikroCAD profiled instrument") and ODSCAD software version 4.0 available from GFMesstechnik GmbH Warthestra3e E21, D1453 Teltow, Berlin, Germany. GFM MikroCAD optical profile includes a sensor for compact optical measurement based on a digital micro-mirror projection consisting of the following components:

A) a 1024 χ 768 direct-control micro-mirror DMD projector

Β) High Resolution CCD Camera (1300 χ 1000pixels)

C) Optical projection adapted to a measuring area of at least 27 χ 22 mm

D) Optical records adapted for a measurement area of at least 27 χ 22 mm, a tripod based on a small stone plate, a cold light source, a measurement, control and evaluation computer, measurement, control and evaluation software, and probes. adjustment for lateral (XY) and vertical (Z) calibration.

E) Schott KL1500 LCD cold light source.

F) Tripod table based on a small stone plate.

G) Computer for measurement, control and evaluation

H) Measurement, Control, and Evaluation SoftwareODSCAD 4.0D) Probes for adjusting lateral (x-y) and vertical (z) calibration.

The GMF MikroCAD optical profiling system measures the height of a sample using the standard projection technique of the digital mirror. The result of the analysis is a mapping of surface height (Z) versus X-Y displacement. The system shall provide a field of view of 27 χ 22 mm with a resolution of 21 μπι. The height resolution is adjusted between 0.10 µm and 1.00 μιη. The height range is 64,000 times the resolution. To measure a fibrous structure sample the following steps are used:

1. Turn on the cold light source. Cold light source adjustments are made to give a reading of at least 2,800 k on the display.

2. Turn on the computer, monitor and printer, and open the software.

3. Select the "Start Measurement" icon from the ODSCAD taskbar then click the "LiveImage" button.

4. Obtain a sample of the fibrous structure that is larger than the field of vision equipment and conditioned at a temperature of about 23 ° C ± 1 ° C (73 ° F ± 2 ° F) and a relative humidity of 50% ± 2. % for 2 hours. Place the sample under the projection head. Position the projection head in a normal position to the surface of the sample.

5. Adjust the distance between the sample and the projection head for a better focus as follows: Press the "Show Cross" button. A blue cross should appear on the screen. Click the "Pattern" button repeatedly to project one of several focus patterns to help you get the best focus. Select a pattern with a cross filament such as one with the square.

Adjust the focus control until the cross filament is aligned with the blue "cross" on the screen.

6. Adjust the brightness of the image by changing the lens aperture through the hole on the side of the projector head and / or changing the camera gain setting on the screen.

When the lighting is optimal, the red circle on the bottom of the screen labeled "I.O" will turn green.

7. Select the measurement type "TechnicalSurface / Rough"

8. Click the "measure" button while keeping the sample in order to avoid blurring the captured image.

9. To transpose the data to the analysis part of the software, click on the clipboard / man icon.

10. Click on the "Draw Cutting Lines" icon. In the captured image, "drag" six (randomly selected) cut lines extending from the center of a positive embossing through the center of a negative embossing to the center of another positive embossing. Click on the "Show Sectional Line Diagram" icon. Make sure the active line is set to line 1. Move the cross hairs to the lowest point on the left side of the image on the computer screen and click with the mouse. Then move the crossed filaments to the lowest point on the right side of the computer screen image on the current line and click with the mouse. Click on the "Align" button by the accented point icon. Click the mouse at the lowest point of this line and then click the mouse at the highest point of the line. Click on the distance icon "Vertical".

Record the distance measurement. Increase the active line to the next line, and repeat the previous steps until all six lines have been measured. Perform the task for four equally spaced sheets throughout the Finished Product Roll, and four finished product rolls, making a total of 16 sheets or 96 registered heights. Average all recorded numbers and expose in mm or μπι as desired. This number is the height of the embossing.

Wet break resistance method

The term "wet breakage resistance" as used in the present invention is a measure of the ability of a fibrous structure, and / or a paper product incorporating a fibrous structure, to absorb energy when wet and subjected to a normal deformation of the said structure. fibrous, and / or said paper product.

Wet breaking resistance can be measured using a Thwing-Albert Cat. N-177 rupture tester, equipped with a 2000 g load cell, commercially available from Thwing-Albert Instrument Company, Philadelphia, PA, USA.

For 1 and 2-layer products having a blade length (DM) of about 280 mm (11 inches), remove two usable units from the roll. Carefully separate the usable units from the perforations, and stack them one above the other. Halve the usable units toward the machine to obtain a stack of four-unit-usable samples. For usable units smaller than 280 mm (11 inches) carefully remove two usable three-unit strips from the roll. Stack the strips so that the perforations and edges match. Carefully remove equal portions of each of the end-use units by cutting in the transverse direction so that the total length of the center unit plus the remaining portions of the two end-use units is about 280 mm (11 inches). Cut the sample stack in half toward the machine to obtain a sample stack of four usable units.

Then the samples are aged in the oven. Carefully attach a paperclip or paper grab to one of the narrow edges. "Spread out" the other end of the sample stack to separate the sheets, allowing air to circulate between them. Suspended sample stack by a claw in a forced vent oven at 105 0C + 1 0C (221 0F + 2 ° F) for five minutes + 10 seconds. After the warm-up period, remove the sample stack from the oven and cool down a minimum of 3 minutes before testing. Take a specimen strip and, holding it by the narrow edges in the transverse direction, immerse the center of the specimen in a container filled with about 25 mm of distilled water. Leave the specimen in the water for four (± 0.5) seconds. Remove and drain for three (3) (± 0.5) seconds, holding the sample so that water runs in the transverse direction of the machine. Perform the test immediately after the drainage step. Place the wet sample on the bottom ring of a break tester sample holder with the outside surface of the sample facing up so that the sample completely covers the open surface of the sample holding ring. If there are wrinkles, discard the samples and repeat the procedure with a new sample. Once the specimen is properly positioned in the lower ring for specimen holding, operate the switch that lowers the upper ring on the break tester. The sample to be tested is now securely attached to the sample holding unit.

Trigger the break test immediately at this point by pressing the start button on the break tester.

A plunger will begin to rise toward the wet surface of the sample. At the point where the sample tears or breaks, record the maximum reading. The plunger will automatically reverse its movement and return to its original position. Repeat this procedure on another three (3) samples for a total of four (4) tests, ie four (4) replicates. Present results as the average of four (4) samples, with a resolution closer to 1 g.

Claims (33)

1. Blanket product, preferably a paper product including one or more layers, the product having a first side and a second side, the said product being characterized by the fact that it includes: - a plurality of distinct embossings extending from the first side to the second side; at least one and preferably a linear embossing plurality extending from the second to the first side, with the blanket product having an average embossing height greater than about 650 μπι. 2. Blanket product according to claim 1, characterized in that the flatness of distinct embossments is arranged in a first standard, and the blanket includes a plurality of linear embossings in a second pattern, with distinct embossings and linear embossings being arranged in a such that at least one of the linear embossing is separated from the linear embossing, alternated by at least one distinct embossing. 3. Blanket product according to claim 2, characterized in that the linear embossing is separated from the alternating linear embossing by at least one distinct embossing. Blanket product according to any of the preceding claims, characterized in that at least one of the linear embossings has a first width and a second width, the first width being less than the second width and providing a space in which at least a distinct embossing is arranged. Blanket product according to any one of the preceding claims, characterized in that it includes at least two adjacent linear embossments, each having a first width and a second width, the first width being less than the second width and the linear embossing being aligned, such that the first width of at least one of the two adjacent linear embossings and the first width of the second of at least one of the two linear embossings form a space in which at least one distinct embossing is arranged. Blanket product according to any one of the preceding claims, characterized in that at least one linear embossing includes at least one partially enclosed region including at least one distinct embossing disposed within the at least partially enclosed region of the linear embossing, preferably: wherein the blanket product includes a plurality of linear embossments having at least partially closed regions, with at least one distinct embossing being disposed within each of the at least partially enclosed regions of the linear embossing. Blanket product according to any one of the preceding claims, characterized in that the blanket includes at least one layer of paper having a non-embossed wet break strength and a wet end strength of the final product greater than about 60% strength. non-embossed wet rupture preferably with the mat having a non-embossed wet rupture resistance and a wet end strength of the final product greater than about 85% of the non-embossed wet rupture resistance. A matting product according to any one of the preceding claims, characterized in that the matting product has an average embossing height greater than about 1000 μπι, preferably greater than about 1250 æm, preferably greater. than about-1450 μπι. 9. Apparatus for the production of a embossed product, characterized in that it comprises: - a first embossing member, - a second embossing member, the first embossing member, having a first surface and a plurality of first embossing elements extending, from the first surface; the plurality of first embossing elements, being distinct embossing elements arranged in a first pattern, the second embossing member having a surface and a plurality of second embossing elements extending from the second surface; the plurality of second embossing elements including at least one linear embossing element and being arranged in a second pattern where said pattern is coordinated with the first pattern and the first and second embossing members being aligned such that the respective first and second coordinate patterns nest so that they engage at a depth greater than about 0.01 mm, preferably greater than about 1.0 mm, preferably greater than about 3.0 mm. 10. Apparatus for the production of a embossed product, characterized by the fact that it comprises: a first embossing member having a first surface and a plurality of first embossing elements extending from the first surface; the plurality of first debossing elements are distinct embossing elements and are arranged in a first pattern having at least one first single pattern unit, each first debossing element having a first distal end and a first distal end area, with the total area of the first areas of distal end of the distinct debonding elements in the first single pattern unit is less than about 5.0 cm 2, preferably less than about 3.0 cm 2, preferably less than about 2.5 cm 2 and a second member embossing, which has a second surface and a plurality of second embossing elements extending from the second surface, the plurality of second embossing elements are linear embossing elements and are arranged in a second pattern, which has at least one second single unit of embossing. , each second embossing element has a second distal end and a second outer area the total area of the second distal end areas of the linear embossing elements in the second single pattern unit is less than about 10 cm2, preferably about 7.5 cm2, preferably less than about 5, 0 cm2, and since the second pattern is coordinated with the first pattern such that when engaged, the first single pattern unit and the second single pattern unit make up a single embossing pattern unit. Apparatus according to claims 9 and 10, characterized in that the second debonding member includes only linear embossing elements. Apparatus according to claims 9 to 11, characterized in that the first embossing elements and / or the second embossing elements comprise a distal end and one or more side walls, at least a portion of the distal end and at least one portion. of one or more sidewalls meeting in a transition region, where: - the transition region has a radius of curvature greater than about 0.075 mm, preferably the first embossing elements and the second embossing elements engage a depth greater than about 1.5 mm and the decurvature radius of the transition region is greater than about 0.5 mm. Apparatus according to claims 9 to 12, characterized in that the distal end of at least one of the first embossing elements is generally curved. Apparatus according to claims 9 to 13, characterized in that the second debonding member includes a plurality of linear embossing elements in a second pattern, wherein: - the first embossing elements and the second embossing elements, when engaged provide a coupling embossing pattern in which at least one of the linear embossing elements is separated from alternating linear embossing elements by at least one first embossing element, preferably each linear embossing element is separated from an alternating linear embossing element. at least one first embossing element. Apparatus according to claims 9 to 14, characterized in that at least one of the linear embossing elements has a first width and a second width, wherein: - the first width is smaller than the second width and provides a space in which at least one distinct deburring member is disposed when the first deburring member and the second embossing member are engaged and, preferably, the second embossing member includes at least two adjacent linear embossing members each with a first width and a the first width is less than the second width and the linear embossing elements are aligned such that the first width of one of the at least two adjacent linear embossing elements and the first width of the second of the at least two embossing elements linear shapes form a space in which at least one distinct embossing element is disposed when the first and second embossing members are the hitched. Apparatus according to claims 9 to 15, characterized in that at least one linear embossing element includes a region at least partially enclosed and the first embossing pattern includes at least one first embossing element which, when engaged with the second embossing pattern, is disposed within the region at least partially enclosed linear embossing element. Apparatus according to claims 9 to 16, characterized in that the second embossing pattern includes a plurality of linear embossing elements including at least partially closed regions and the first embossing pattern includes a plurality of first embossing elements which, when engaged with the second embossing pattern, at least some of the plurality of first embossing elements are arranged within at least partially closed regions of the linear embossing elements. Apparatus according to claim 10, characterized in that the single-defrosting pattern unit has a flat projected area and the total area of the first distal ends in the single-embossing pattern unit is less than about 20%. preferably less than about 15%, preferably less than about 10% of the flat projected area of the single embossing pattern unit. Apparatus according to claims 10 and 18, characterized in that the single embossing pattern unit has a flat projected area and the total area of the second distal ends in the single embossing unit is less than about 40%, preferably less than about 30%, preferably less than about 20%, preferably less than about 15% of the flat projected area of the single embossing pattern unit. Apparatus according to claims 10 and 18 to 19, characterized in that the ratio of the total area of the second distal ends of the second single pattern unit to the total area of the first distal ends of the first single pattern unit is less than about preferably less than about 2: 1, preferably less than about 1: 1. Apparatus according to claims 10 and 18 to 20, characterized in that the first embossing member and the second embossing member are aligned such that the first pattern and the second pattern are aligned to engage one another. depth greater than about 0.01 mm, preferably greater than about 1.0 mm, preferably greater than about 2.0 mm. Apparatus according to claims 10 and 18 to 21, characterized in that the linear deformation elements have a width of less than about 15 mm, preferably less than about 7.5 mm, preferably less than that about 2.5 mm. 23. Method for producing an embossed product, characterized in that it comprises the steps of: (a) providing one or more layers of material to a embossing apparatus, including a first and second married embossing members; and (b) passing one or more layers of the material between the first and second embossing members to emboss the mat; wherein: the first embossing member has a distinct plurality of embossing elements extending from a first surface thereof and having a pattern, - the second embossing member has at least one linear embossing element extending from a second surface thereof; wherein at least one linear debonding element is coordinated with the pattern of the first embossing elements; e- the first embossing member and the second embossing member are aligned such that the respective coordinate patterns of the first embossing elements nest with at least one linear embossing element at a engagement depth greater than about -0.01 mm preferably greater than about 1.0 mm, preferably greater than about 3.0 mm. 24. Method for the production of a fiber matting product Characterized by the steps of: (a) providing one or more layers of matting material to a embossing apparatus; the apparatus including a first and second married embossing members; and (b) passing one or more layers of the material between the two embossing members, wherein: the first embossing member has a plurality of distinct embossing elements extending from a first surface thereof and arranging a pattern; least one linear embossing element extending from a second surface thereof, at least one linear embossing element is coordinated with the pattern of the first embossing elements; and c) engaging the first and second embossing members to emboss the mat such that the respective coordinate pattern of distinct embossing elements aligns with at least one linear embossing element to emboss said one or more layers of material, wherein embossing said one or more layers of the material results in an embossed layer or layers of material, comprising a plurality of embossments with an average height of at least about 650 μιη, preferably at least about-1,000 μπι, preferably at least about 1,250 μιη, preferably at least about 1,450 μπι, preferably at least about 2,000 μιη. 25. Method for producing an embossed product, characterized in that it comprises the steps of: (a) feeding said one or more layers of material into a embossing apparatus, including the first and second married embossing members; and (b) passing said one or more layers of material between the first and second embossing members to emboss the web, wherein: the first embossing member has a first surface and a plurality of first embossing elements extending from the first surface; First embossing elements are distinct embossing elements and are arranged in a first pattern that has a first repeating single pattern unit - each first embossing element has a first distal end and a first distal end area - the total area of the first distal ends distinct embossing elements in the first single repeat pattern unit is less than about 5.0 cm2; - the second embossing member has a second surface and a plurality of second embossing elements extending from the second surface; plurality of second embossing elements are linear embossing elements and are arranged in a second pattern having a second single repeating pattern unit; each second embossing element has a second distal end and a second distal end area; - the total area of the distal second ends of the linear embossing elements on the second single repeating pattern unit is less than about 10 cm2; - the second pattern is coordinated with the first pattern such that when engaged, the first single repeat pattern unit and the second single repeat unit make up a single embossing repeat pattern unit . A method according to claims 24 and 25, characterized in that the first embossing elements nest with the second embossing elements at a coupling depth greater than about -0.01 mm, preferably larger. than about 2.0 mm. A method according to claims 23 and 25, further comprising the step of engaging the first and second embossing members to emboss the web such that the first embossing elements nest as linear embossing elements for embossing said one or more layers of material, wherein embossing said one or more layers of material results in an embossed layer or layers of material comprising a plurality of embossments having an average height of at least about 650 μιη, preferably at least about 1,000 μπ \, preferably at least about 1,250 μιη, preferably at least about 1,450 μπι. A method according to claims 23 to 27, characterized in that the second debonding member includes only linear embossing elements. A method according to claims 23 to 28, characterized in that the discrete embossing elements and / or the linear embossing elements comprise a distal end and at least one sidewall, at least a portion of the distal end and at least one portion. at least one sidewall is found in a transition region, where: - the transition region has a radius of curvature greater than about 0.075 mm, preferably the distinct embossing elements and linear embossing elements engage the a depth greater than about 1.5 mm and the decurvature radius of the transition region is greater than about 0.5 mm. A method according to claims 23 to 29, characterized in that one or more layers of material have an inner surface and an outer surface, wherein the distinct embossing elements are shaped to deform said one or more layers of material. Toward the inner surface and at least a linear embossing element is configured to form said one or more layers of material towards the outer surface. A method according to claims 23 to 30, characterized in that at least one of said layers one or more layers of material includes at least some cellulosic fibers and the method further comprises the step of providing heat, moisture and / listen to the blanket before the embossing of the blanket. A method according to claims 23 to 31, characterized in that the layer or layers of material comprises a paper web which has a non-embossed wet breaking strength and the embossing paper has a higher wet breaking strength. of about 60% of the non-embossed wet break strength, preferably greater than about 75% of the non-embossed wet break strength, preferably greater than about 85% of the non-embossed wet break strength. 33. Paper product, characterized in that it is made of the method according to any one of claims 23 to 32.