EP1099539B1 - Produit papetier absorbant gaufré mono- ou multi-couche - Google Patents

Produit papetier absorbant gaufré mono- ou multi-couche Download PDF

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Publication number
EP1099539B1
EP1099539B1 EP00310059A EP00310059A EP1099539B1 EP 1099539 B1 EP1099539 B1 EP 1099539B1 EP 00310059 A EP00310059 A EP 00310059A EP 00310059 A EP00310059 A EP 00310059A EP 1099539 B1 EP1099539 B1 EP 1099539B1
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EP
European Patent Office
Prior art keywords
ply
sheet
undulations
undulatory
emboss
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP00310059A
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German (de)
English (en)
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EP1099539A1 (fr
Inventor
Thomas N. Kershaw
Dale T. Gracyalny
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Georgia Pacific Consumer Operations LLC
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Georgia Pacific LLC
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Publication date
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Priority claimed from US09/709,139 external-priority patent/US6348131B1/en
Priority claimed from US09/709,185 external-priority patent/US6455129B1/en
Application filed by Georgia Pacific LLC filed Critical Georgia Pacific LLC
Publication of EP1099539A1 publication Critical patent/EP1099539A1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/12—Crêping
    • B31F1/122—Crêping the paper being submitted to an additional mechanical deformation other than crêping, e.g. for making it elastic in all directions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/12—Crêping
    • B31F1/14—Crêping by doctor blades arranged crosswise to the web
    • B31F1/145—Blade constructions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0717—Methods and means for forming the embossments
    • B31F2201/072—Laser engraving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0728—Material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0733—Pattern
    • B31F2201/0735—Pattern inclined with respect to the axis of the roller
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0738—Cross sectional profile of the embossments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0756—Characteristics of the incoming material, e.g. creped, embossed, corrugated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0758—Characteristics of the embossed product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0758—Characteristics of the embossed product
    • B31F2201/0761—Multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0784—Auxiliary operations

Definitions

  • the invention relates to embossed absorbent paper products, for example, paper towels, tissue and napkins, in which an improved embossing arrangement is used which is particularly suitable for embossing paper products which have been processed so as to include undulations in the sheet.
  • Absorbent paper products such as paper towels, napkins and toilet tissue are widely used on a daily basis for a variety of household needs. These products are commonly produced by depositing cellulosic fibers suspended in water on a moving foraminous support to form a nascent web, removing water from the nascent web, adhering the dewatered web to a heated cylindrical Yankee dryer, and then removing the web from the Yankee with a creping blade which, in conventional processes, imparts crepe bars, ridges or undulations whose axes extend generally transversely across the sheet (the cross-direction). Products produced in this conventional fashion may often be considered lacking in bulk, appearance and softness and so require additional processing after creping, particularly when produced using conventional wet pressing-technology. Absorbent sheet produced using the through air drying techniques normally have sufficient bulk but may have an unattractive appearance or undesirable stiffness.
  • an overall pattern is imparted to the web during the forming and drying process by use of a patterned fabric having designs to enhance appearance.
  • a patterned fabric having designs to enhance appearance.
  • through air dried tissues can be deficient in surface smoothness and softness unless strategies such as calendering, embossing, chemical softeners and stratification of low coarseness fibers on the tissue's outer layers are employed in addition to creping.
  • the processes of Marinack et al . can be used to provide not only desirable premium products including high softness tissues and towels having surprisingly high strength accompanied by high bulk and absorbency, but also to provide surprising combinations of bulk, strength and absorbency which are desirable for lower grade commercial products.
  • the processes of Marinack et al . can be used to provide not only desirable premium products including high softness tissues and towels having surprisingly high strength accompanied by high bulk and absorbency, but also to provide surprising combinations of bulk, strength and absorbency which are desirable for lower grade commercial products.
  • the objective of the undulatory creping blade of Marinack et al. is to work the web more effectively than previous creping arrangements. That is, the serrulations of the creping blade operate to contact the web rotating off of the dryer in such a way that a part of the web contacts the tops of the serrulations while other parts of the base sheet contact the valleys, thereby forming undulations in the base sheet.
  • This creping operation effectively breaks up the hydrogen and mechanical bonds which link the cellulosic fibers together, thereby producing a smoother, bulkier and more absorbent sheet, which is well suited for consumer use.
  • Creping in accordance with the Marinack et al. patents creates a machine direction oriented shaped sheet which has higher than normal stretch in directions other than the machine direction, that is, particularly high cross-direction stretch.
  • embossing can enhance the bulk, softness and appearance of the products. It has been found that the proper selection of emboss element spacing, distribution and orientation can positively impact on the retention or enhancement of the beneficial properties caused by the creping of the web with an undulatory blade. Conversely, improper selection of the emboss element spacing, distribution and orientation can negatively impact, or cause a complete loss of, the beneficial properties caused by the creping of the web with an undulatory blade.
  • Undulatory blade creping creates a machine direction oriented shaped sheet which has higher than normal stretch in the directions other than the machine direction.
  • the present invention recognizes and takes this three dimensional sheet shape and stretch into consideration.
  • the application of embossing to the biaxially undulatory sheet is done in a way that the emboss process provides the desired modifications to the sheet with controlled extension and disruption of the localized bonds and fiber shapes imparted by the undulatory blade creping.
  • the parameters for embossing webs that have undulations extending longitudinally along a principal undulatory axis and optionally include secondary undulations which extend in the cross (transverse direction) of the web.
  • the parameters must accommodate: the distance at which the undulations are spaced, the total surface area of the design (embossing) elements, the width and length of the embossing elements and the aspect ratio of the elements, and the angular orientation of the embossing elements with respect to the undulations.
  • the embossing parameters of the present invention are applicable to paper webs having undulations running in either the machine or cross-directions regardless of the means used to apply the undulations to the web.
  • the web to be processed according to the present invention can be made using non-recycled and recycled fibers well known to the skilled artisan.
  • Preferred fibers are cellulose based fiber and may include softwood, hardwood, chemical pulp obtained from softwood and/or hardwood by treatment with sulfate or sulfite moieties, mechanical pulp obtained by mechanical treatment of softwood and/or hardwood, recycle fiber, refined fiber and the like.
  • Papermaking fibers used to form the soft absorbent products of the present invention may include cellulosic fibers commonly referred to as wood pulp fibers, liberated in the pulping process from softwood (gymnosperms or coniferous trees) and hardwoods (angiosperms or deciduous trees).
  • Cellulosic fibers from diverse material origins may be used to form the web of the present invention, including non-woody fibers liberated from sabai grass, rice straw, banana leaves, paper mulberry (i.e. bast fiber), abaca leaves, pineapple leaves, esparto grass leaves, and fibers from the genus hesperalae in the family agavaceae.
  • the recycled fibers used in accordance with the present invention may contain any of the above fiber sources in different percentages and can be useful in the present invention.
  • the furnish may include non-cellulosic components including synthetic fiber if so desired.
  • Papermaking fibers can be liberated from their source material by any one of the number of chemical pulping processes familiar to the skilled artisan including sulfate, sulfite, polysulfide, soda pulping, etc.
  • the pulp can be bleached if desired by chemical means including the use of chlorine, chlorine dioxide, oxygen, etc.
  • papermaking fibers can be liberated from source material by any one of a number of mechanical/chemical pulping processes familiar to anyone experienced in the art including mechanical pulping, thermomechanical pulping, and chemithermomechanical pulping.
  • the mechanical pulps can be bleached, if one wishes, by a number of familiar bleaching schemes including alkaline peroxide and ozone bleaching.
  • Fibers for use according to the present invention can be obtained from recycling of pre-and post-consumer paper products.
  • Fiber may be obtained, for example, from the recycling of printers trims and cuttings, including book and clay coated paper, post consumer paper including office and curbside paper recycling and old newspaper.
  • the various collected papers can be recycled using means common to recycled paper industry.
  • the papers may be sorted and graded prior to pulping in conventional low-, mid-, and high-consistency pulpers. In the pulpers the papers are mixed with water and agitated to break the fibers free from the sheet. Chemicals common to the industry may be added in this process to improve the dispersion of the fibers in the slurry and to improve the reduction of contaminants that may be present.
  • the slurry is usually passed through various sizes and types of screens and cleaners to remove the larger solid contaminants while retaining the fibers. It is during this process that such waste contaminants as paper clips and plastic residuals are removed.
  • the pulp is then generally washed to remove smaller sized contaminants consisting primarily of inks, dyes, fines and ash.
  • This process is generally referred to as deinking.
  • Deinking in the modem sense, refers to the process of making useful pulp from wastepaper while removing an ever-increasing variety of objectionable, noncellulosic materials.
  • One example of a deinking process by which fiber for use in the present invention can be obtained is called floatation. In this process small air bubbles are introduced into a column of the furnish. As the bubbles rise they tend to attract small particles of dye and ash. Once upon the surface of the column of stock they are skimmed off. At this point the pulp may be relatively clean but is often low in brightness. Paper made from this stock can have a dingy, gray appearance, not suitable for near-premium product forms.
  • Bleaching can be accomplished by a number of means including, but not limited to, bleaching with chlorine, hypochlorite, chlorine dioxide, oxygen, peroxide, hydrosulfite, or any other commonly used bleaching agents.
  • the types and amounts of bleaching agents depend a great deal on the nature of the wastepaper being processed and upon the level of desired brightness.
  • unbleached waste papers can have brightness levels between 60 to 80 on the G.E. brightness scale, depending upon the quality of the paper being recycled.
  • Bleached waste papers can range between the same levels and may extend up to about 90, however, this brightness level is dependent upon the nature of the waste papers used. The particular brightness level selected will likewise depend on the product desired.
  • creping process is illustrated in Figure 1.
  • a web of single-ply paper tissue sheet 20 is creped from the surface of a Yankee dryer 22 using an undulatory creping blade 24.
  • Creping blade 24 imparts to the sheet undulations which extend in the longitudinal direction (machine direction) in addition to transverse crepe bars as is discussed and illustrated in detail to follow.
  • creped sheet 20 may be calendered by passing it through the nip of a pair of calender rolls 26a and 26b which impart smoothness to the sheet while reducing its thickness. After calendering, the sheet is wound on reel 28.
  • emboss sheet 20 it is unwound from reel 28 in a converting operation and passed through the nip of a pair of embossing rollers 30a, 30b. Thereafter sheet 20 proceeds to further process steps such as perforating, cutting the sheet into the widths suitable for end users and winding of same unto tubes.
  • rollers 30 may be of either the matched or unmatched type and can be of either steel or rubber.
  • Matched embossing rollers means that the male embossing elements, carried by one roller, are engraved first and the female elements carried by the other rollers are subsequently made from the male elements, or vice versa, so that both elements are virtually inverse or reciprocal images of each other within the practicalities of manufacturing tolerances. This is in contrast to unmatched embossing rollers in which the male and female embossing elements are not identical in shape, but still are positioned relative to each other in registry such that they engage.
  • the present invention is applicable to uncreped as well as to both dry and wet creping processes.
  • a dry creping process the moisture content of the web when it contacts undulatory creping blade 24 is usually in the range of 2 to 8 percent which permits the web to be calendered and wound on reel 28.
  • a wet creping process the consistency of the web contacting undulatory creping blade 24 is usually in the range of 40 to 75 percent (solids content).
  • the drying process is completed by use of one or more heated dryers through which the web is wound. These dryers are used to reduce the water content to its desired final level, usually from 2 to 8 percent.
  • the dried sheet is then optionally calendered and wound on reel 28.
  • Figures 2 and 3 illustrate a portion of undulatory creping blade 24 which extends indefinitely in length, typically exceeding 100 inches in length and often reaching over 26 feet in length to correspond to the thickness of the Yankee dryer on the larger modern paper machines.
  • the thickness of blade 24 indicated at 25 is usually on the order of fractions of an inch.
  • an undulatory cutting edge 34 is defined by serrulations 36 disposed along, and formed in, one edge of blade 24 so that an undulatory engagement surface 38, engages Yankee dryer 22 during use.
  • the shape of undulatory cutting edge 34 strongly influences the configuration of the creped web, in that the peaks and valleys of serrulations 36 form undulations in web 20 whose longitudinal axes lies along the machine direction.
  • the number of serrulations 36 can range from 10 to 50 per inch depending upon the desired number of undulations per inch in the finished web.
  • Figure 4 is a close up illustration of the configuration of web 20 after it has been creped by the action of an undulatory creping blade such as that shown in Figures 2 and 3, but before being embossed.
  • Web 20 is characterized by a reticulum of intersecting crepe bars 39 extending transversely in the cross-direction which are formed during the creping of web 20 from Yankee dryer 22.
  • crepe bars 39 form a series of relatively small undulations 40 whose longitudinal axes extend in the cross-direction.
  • each undulation 42 includes an upwardly disposed portion (peak) 44 and a downwardly disposed portion (valley) 46.
  • valley upwardly disposed portion
  • valley downwardly disposed portion
  • undulations 42 extend in the machine direction and are larger than undulations 40 formed by creped bars 39 extending in the cross-direction.
  • web 20 has undulations running in both the machine and cross-direction forming a biaxially undulatory web.
  • the present invention provides embossing parameters which enhance the desirable properties of the web shown in Figure 4.
  • the absorbent sheet in accordance with the invention may be provided with an undulatory structure or a biaxially undulatory structure such as is shown in Figure 4 by any suitable technique for making absorbent sheet.
  • One technique, used in both creped and uncreped through-air drying processes involves wet-shaping the web or sheet on a fabric.
  • a method of forming tissue in United States Patent No. 5,607,551 to Farington, Jr.et al. wherein the functions of providing machine direction stretch and cross machine direction stretch are accomplished by providing a wet end rush transfer and a particular through air drying fabric design respectively.
  • the process according to the '551 patent does not include a Yankee dryer or creping; however, this process may be used to provide undulatory structures useful in connection with the present invention.
  • the disclosure of United States Patent No. 5,607,551 is hereby incorporated by reference.
  • Absorbent sheet with undulatory structures may also be prepared in the absence of wet-end pressing or undulatory creping.
  • This process may likewise be employed to prepare an undulatory substrate for embossing in accordance with the present invention.
  • the disclosure of United States Patent No. 3,994,771 is hereby incorporated by reference in its entirety into this application.
  • Figures 5(a) and 5(b) There is shown in Figures 5(a) and 5(b) a conventional absorbent sheet with an emboss pattern.
  • the sheet has a generally smooth finish and does not include undulations extending longitudinally in the machine direction.
  • Figure 5(a) is a photograph at 4X magnification of the surface
  • Figure 5(b) is a photograph at 6X magnification of the surface of the sheet.
  • the embossments cover more than about 50 percent of the surface area.
  • the machine direction is the shorter (vertical) direction, while the longer dimension (horizontal) is in the cross-direction of the sheet.
  • Figures 6(a) through 8(b) are similarly oriented as discussed in more detail hereinafter.
  • Figures 6(a) and 6(b) there is shown in Figures 6(a) and 6(b) an embossed absorbent sheet with an emboss pattern useful in connection with the present invention.
  • Figure 6(a) is a photograph of a portion of the sheet at 4X magnification
  • Figure 6(b) is a photograph of the sheet at 6X magnification.
  • the machine direction of the sheet is in the vertical (shorter) direction of the photograph
  • the cross-direction of the sheet is in the larger (horizontal) direction.
  • the sheet has an undulatory structure in the machine direction, crepe bars in the cross-direction, as well as a floral emboss pattern made up of a plurality of design elements.
  • Figures 6(a) and 6(b) can be characterized as follows: there is an upper circular portion having an aspect ratio of approximately 0, thus having an angle with the machine direction of 1; a central stem portion having an aspect ratio of roughly 3, also having an angular relation to the machine direction of 0° and a leaf portion having an aspect ratio of about 1.5, having a characteristic angle with the machine direction of about 25° to about 35°.
  • the sheet may also be described as having primary undulations extending along a principal undulatory axis of the sheet (in this case the machine direction), as well as having secondary undulations substantially perpendicular to the primary undulations (in this case the cross-direction of the sheet) such that the sheet is biaxially undulatory.
  • This structure is conveniently provided by way of an undulatory creping blade as noted above, but may also be accomplished in connection with wet shaping or fabric molding.
  • Figure 7(a) a photograph of another sheet provided with an emboss pattern useful in connection with the invention, wherein the photograph is at 6X magnification and there is provided a plurality of repeating hexagonal embossments in accordance with the invention.
  • the machine direction of the sheet is the vertical (shorter) side of the photograph, while the cross-direction of the sheet is the longer (horizontal) side of the photograph.
  • the sheet of Figure 7(a) was produced with matched steel embossing rolls. Two features to note in connection with the sheet of Figure 7(a) are: (1) the embossments have relatively "soft" edges due to local elongation and the longitudinal undulations are offset laterally by the embossments.
  • Figure 7(b) is also a photograph at 6X magnification of a sheet in accordance with the present invention.
  • the machine direction is, here again, in the shorter (vertical) direction of the photograph and the cross-direction is along the longer (or horizontal) side of the photograph, as mounted.
  • the sheet of Figure 7(b) is, in most aspects, similar to the sheet of Figure 7(a); however, the edges of the embossments are sharp.
  • the sheet of Figure 7(b) was made by way of rubber to steel embossing.
  • the embossments are operative to laterally displace the vertical or machine direction undulations due to movement allowed by cross-direction stretch.
  • FIG. 8(a) is a photograph at 6X magnification
  • Figure 8(b) is a photograph of the sheet of Figure 8(a) at 4X magnification.
  • the machine direction is along the shorter edge of the photograph, with the cross-direction being perpendicular thereto.
  • the embossments are arranged in a plurality of diamond-like arrays, repeating over the surface of the sheet.
  • the 0 individual embossments have an aspect ratio of about 1.5 and one spaced at a distance of about 1.5 times the separation distance between longitudinal undulations as further described below.
  • Figure 9 depicts schematically a portion of a floral design element 50 such as a petal shown on Figures 6(a) and 6(b) including a first elongate embossment 52 opposing a second elongate embossment 54.
  • the embossments are provided on a base sheet indicated generally at 56 provided with a plurality of undulations 58, 60, 62 which repeat over the surface of sheet 56. The undulations extend in the machine direction 64 of the sheet.
  • Design element 50 has a characteristic maximum width, 66, also labeled W in the figure and a characteristic maximum length, L, indicated at 68.
  • the aspect ratio, L:W, is characteristically from about 1 to about 4.
  • Length, L is disposed about a direction, L', indicated at 70 which is at an angle, ⁇ , shown at 72, with the machine direction (MD) 64.
  • Longitudinal undulations such as undulations 58-62 cover the base sheet in a repeating pattern typically with a frequency of from about 1 to about 50 undulations per inch with from about 12 to about 25 undulations per inch being more typical.
  • the undulations are thus spaced at a plurality of crest to crest distances, S1 , S2, S3, indicated at 74, 76, 78 typically in some embodiments at slightly more than a millimeter; 1.5 millimeters or so also being typical.
  • S1 , S2 and S3 may be the same in the case of uniform spacing, or may differ if so desired. In the case of non-uniform spacing, the respective distances may be averaged when compared with emboss distances and design element widths.
  • embossments 52, 54 may define a design element of an embossing pattern applied in accordance with the present invention
  • the design elements may also be in the form of embossed shapes, such as hexagons, diamonds, square, ovals, rectangular structures and the like which are uniformly repeating over the surface of the sheet or are provided in clusters.
  • the emboss design elements have an aspect ratio, L:W, greater than 1 and are aligned in the machine direction such that ⁇ is 0.
  • Figure 10 depicts the embossed sheet of Figures 6(a) and 6(b).
  • the sheet 80 has a plurality of longitudinal undulations 82, 84, 86 and so forth extending in the machine direction 88.
  • a flower design element 90 is essentially circular, having an aspect ratio of 1 and making an angle ⁇ with the machine direction 88 of 0.
  • a leaf design element, 94 has an aspect ratio of roughly 1.5 and makes an angle ⁇ with the machine direction of between about 25° and 35°.
  • sheet 80 is a creped sheet having repeating crepe bars 96, 98, 100 and so forth in the cross-direction.
  • the longitudinal undulations have a frequency of about 20 undulations per inch, while the frequency of the crepe bars is much higher.
  • Sheet 102 has a plurality of design elements in the form of embossed hexagons 104, 106, 108 and so forth which repeat over the surface of the sheet as shown. Longitudinal undulations are provided at a frequency of about 20 undulations per inch. Interestingly, some of the undulations, such as longitudinal undulations 110 conform to a serpentine shape in the machine direction due to the embossments. This is believed due to the property of relative high cross-direction stretch of the inventive embossed sheets. Thus, the design elements may be continuously embossed shapes such as hexagons.
  • Figure 12 shows the sheet of Figures 8(a) and 8(b) at 112.
  • the emboss pattern of the invention is embodied in diamond-like clusters 114 of elongate embossments 116 having a collective aspect ratio of about 1.
  • Individual embossments 116 have an aspect ratio of 1.5 and a width, W, of about 1 mm.
  • the longitudinal undulations are spaced at 20 per inch, thus having a spacing, S, of about 1.3 mm.
  • the individual embossments are spaced at a distance, D, of about 1.4 mm.
  • the ratio ofD:S is about 1 or more.
  • Figure 13 is an illustration schematically depicting one means for carrying out embossing in accordance with the present invention in connection with a multiple ply web.
  • first and second plies are prepared and creped so as to include the machine direction undulations described in detail above.
  • a first paper ply 120 is conveyed past a series of idler rollers 122 towards a nip 123 located between a steel engraved roll 124 and a rubber roll 126 where ply 120 will be embossed as set forth in detail above.
  • Engraved roll 124 rotates in a clockwise direction while rubber roll 126 rotates in a counterclockwise direction.
  • a second tissue ply 128 is conveyed around idler rollers 132 and is then passed to a nip 133 located between a rubber roll 134 and engraved roll 124 where ply 128 will be embossed. Thereafter second ply 128 winds around engraved roll 124 where it passes through nip 123 located between steel engraved roll 124 and rubber roll 126 wherein plies 120, 128 will be joined together into a two ply product 136 which is conveyed by idler rollers 138 to take-up reel 140.
  • the use of an arrangement with two separate nips, whose pressure can be independently adjusted, permits the embossing depth of each ply to be different from that of the other.
  • Engraved roll 124 is engraved with the embossing patterns described in detail herein and embosses the web in accordance with the principles of the present invention.
  • rolls 126, 134 can be steel rolls matched or unmatched (as described above) to engraved roll 124.
  • proper bonding may require the use of glue.
  • a gluing roller 142 is positioned so as to contact ply 128 as it wraps around roll 124 so as to apply a thin film of glue to ply 128. The glue applied to ply 128 will then bind ply 128 to ply 120 as they pass through nip 123.
  • Figure 13 illustrates machinery for simultaneously carrying out the embossing and bonding of the plies. However, the bonding and embossing operations need not be carried out simultaneously
  • Figure 14 illustrates apparatus in which the bonding of the plies and the embossing is carried out in separate operations.
  • a first supply reel 150 provides a first ply 152 of paper processed so as to include machine direction undulations and a second supply reel 154 provides a second ply 156 of paper including machine direction undulations.
  • Plies 152, 156 pass to a nip 158 formed between a pair of bonding rolls 160, 162 which are constructed in the known manner so as to bind plies 152, 156 together.
  • a glue applying roll 163 will apply a film of glue to ply 152 to positively bind the plies together.
  • the now two ply web 164 proceeds to a nip 166 formed between embossing rolls 168, 170 for embossing of two ply web 164 in accordance with the principles of the present invention.
  • Embossing rolls 168, 170 may again be constructed from steel or resilient materials and may be matched of unmatched.
  • two ply web 164 may proceed to further processing steps such as perforating, cutting into consumer widths and winding onto rolls.
  • Figure 15 illustrates an arrangement in which the embossing of the plies is carried out prior to the bonding of the plies together.
  • a first supply reel 180 provides a first ply 182 of paper which is processed so as to impart undulations as described in detail above.
  • First ply 182 then passes through a nip formed between a first pair 184,186 of embossing rolls for embossing in accordance with the principles of the present invention.
  • a second supply reel 188 provides a second ply 190 of paper which includes the machine direction undulations as described above.
  • Second ply 190 then passes through a nip formed between a second pair 192, 194 of embossing rolls for embossing in accordance with the present invention. Thereafter ply 182 and ply 190 pass to the nip formed by a pair of confronting binding rolls 196, 198 for binding into a two ply web 200. If required a glue roller 202 can be utilized to apply a film of glue between plies 182,190 before binding. Embossing rolls 184, 186, 192, 194 may also be constructed from steel or resilient materials and may be matched or unmatched. After embossing, two ply web 200 may proceed to further processing steps such as perforating, cutting into consumer widths and winding onto rolls.
  • each ply may be may be displaced in the cross direction so that the "peaks" of the undulations of one ply are either bound with the peaks or the "valleys" of the undulations of the other ply.
  • the peaks of one ply are arranged to nest in the valleys of the other ply a relatively dense two ply web will be formed.
  • the peaks and valleys of one ply are opposed to the peaks and valleys of the other ply a very thick, soft two ply web will be formed. In this manner the density of the two ply web can be readily controlled, depending on the application for which the paper product is intended.
  • each of the plies of the webs need not be processed to include machine direction undulations such as those produced by an undulatory creping blade as one or more plies of a multiple ply web can be free of undulations and free of embossments.
  • a multi-ply absorbent sheet provided with primary undulations extending along a principal undulatory axis of the sheet, the primary undulations being laterally spaced apart a distance, S, while the single-ply absorbent sheet is provided with an emboss pattern comprising a plurality of design elements wherein up to about 50 percent of the surface area of said absorbent sheet is embossed.
  • the sheet is characterized in that each design element of the emboss pattern has a characteristic emboss element lateral width, W, and a characteristic emboss element, length, L, along a direction L' and wherein the ratio of W:S for each design element is from about 1 to about 4.
  • the ratio of W:S for each design element is from about 1.5 to about 3, and usually the aspect ratio, L:W for each design element is at least about 1.1.
  • An aspect ratio, L:W for each design element is at least about 1.2 is preferred in some cases, but may be from about 1.1 to about 4, or from about 1.2 to about 2.5.
  • the direction, L' makes an angle ⁇ of less than about 45 degrees with the principle undulatory axis of the sheet in preferred cases while instances wherein L', makes an angle ⁇ of less than about 30 degrees with the principal undulatory axis of the sheet are preferred.
  • An aspect ratio, L:W for each design element of about 1 is preferred in some embodiments.
  • the sheet is provided with secondary undulations substantially perpendicular to the primary undulations such that the secondary undulations extend along a secondary undulatory axis of the sheet.
  • the sheet may have from about 10 to about 50 primary undulations per inch extending along the principal undulatory axis and from about 10 to about 150 secondary undulations per inch extending along the secondary undulatory axis of said sheet.
  • the sheet has from about 12 to about 25 primary undulations extending along the principal undulatory axis of the sheet.
  • the secondary undulations have a frequency greater than that of said primary undulations and the sheet includes a creped ply wherein the primary undulations extend in the machine direction of the ply and are longitudinally extending undulations.
  • the ply may have from about 10 to about 150 crepe bars per inch extending in the cross-direction of the ply, and may be prepared with an undulatory creping blade operative to form the longitudinally extending undulations.
  • the creped ply has from about 10 to about 50 longitudinally extending undulations per inch, and more typically, from about 12 to about 25 longitudinally extending undulations per inch.
  • the crepe bars likewise have a frequency greater than that of the longitudinally extending undulations; generally with a frequency of the crepe bars from about 2 to about 6 times the frequency of the longitudinally extending undulations. More typically, the frequency of the crepe bars is from about 2 to about 4 times the frequency of the longitudinally extending undulations.
  • the emboss pattern does not substantially alter the cross-direction stretch of the absorbent sheet from which the embossed absorbent sheet was prepared.
  • the cross-direction stretch of the sheet is from about 0.2 to about 0.8 times the machine direction stretch of the sheet, whereas a cross-direction stretch of the sheet from about 0.35 to about 0.8 times the machine direction stretch of said sheet is more preferred.
  • the distance between design elements, D is greater generally than S , typically from about 1.5 to about 3 times S.
  • the design elements have an emboss depth of from about 15 to about 30 mils in many cases and from about 10 to about 25 percent of the surface area of the sheet is embossed.
  • the absorbent sheet may be a tissue product having a basis weight of from about 5 to about 40 pounds per 3,000 square foot ream, or a towel product having a basis weight of from about 15 to about 45 pounds per 3,000 square foot ream. In any case, the sheet may be prepared utilizing recycle furnish.
  • a multi-ply sheet provided with primary undulations extending along a principal axis of the sheet, the primary undulations is laterally spaced apart a distance, S, and the single-ply absorbent sheet being further provided with an emboss pattern comprising a plurality of embossments of width, W, and length, L, wherein the lengths are along a direction, L', and wherein the embossments cover no more than about fifty percent of the area of said absorbent sheet.
  • the embossments are spaced apart from each other at a distance, D, with the proviso that at least one of the ratios of W:S and D:S is from about 1 to about 4.
  • At least one of the ratios of W:S and D:S is from about 1.5 to about 3.5, and the embossments cover no more than about 25 percent of the surface area of the sheet.
  • the ratio of cross-direction stretch to machine direction stretch is from about 0.2 to about 0.5, whereas from about 0.35 to about 0.5 is more typical.
  • the principal undulatory axis is along the machine direction of said sheet, and the primary undulations are non-compacted relative to the other portions of the sheet.
  • a method of making a multi-ply absorbent sheet comprising: preparing a plurality of absorbent plies, and bonding the plies, where the sheet includes a plurality of primary undulations extending along a principal undulatory axis of the sheet, said undulations being spaced apart a distance, S; and providing an emboss to said sheet, wherein said emboss pattern comprises a plurality of design elements wherein up to about 50 percent of the surface area is embossed, characterised in that said design elements have a characteristic design element width, W, and a characteristic emboss length, L, along a direction, L', and wherein the ratio of W:S for each design element is from about 1 to about 4.
  • the sheet may include at least one unembossed ply if so desired and at least one of the plies may be embossed prior to bonding the plies.
  • the multi-ply absorbent sheet is embossed simultaneously with the bonding of said plies or the sheet is embossed subsequent to the bonding of the plies.
  • the sheet may be a biaxially undulatory sheet with secondary undulations extending in a direction substantially perpendicular to the principal undulatory axis.
  • the process includes at least one creped ply.
  • the ratio of W:S for each design element may be from 1.5 to 3.
  • the aspect ratio, L:W may be about 1 or may be at least 1.1, suitably 1.2; for example, from 1.1 to 4, preferably 1.2 to 2.5.
  • the direction, L' may make an angle of less than 45°, preferably less than 30°, with the machine direction of the said sheet.
  • a method of providing an absorbent ply in a multi-ply absorbent product comprising: preparing a web comprising cellulosic furnish; applying the web to a Yankee dryer; creping the web from the Yankee dryer with an undulatory creping blade at a consistency of between about 40 and about, 98 percent, such that the creped ply is provided with crepe bars extending laterally in the cross-direction and undulations extending longitudinally in the machine direction, said undulations being spaced apart a distance, S; embossing the ply with an emboss pattern comprising a plurality of design elements wherein up to about 50 percent of the area of the absorbent ply is embossed, characterized in that each design element of said emboss pattern has a characteristic emboss element lateral width, W, and wherein the ratio of W:S for each design element is from about 1 to about 4; and incorporating said ply into said multi-ply absorbent product.
  • the ply may be embossed prior to being incorporated into the muli-ply absorbent product or the ply may be embossed subsequent to being incorporated into said multi-ply absorbent product. Most preferably, the ply is embossed simultaneously with being incorporated into the multi-ply absorbent product.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Paper (AREA)
  • Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
  • Sanitary Thin Papers (AREA)
  • Absorbent Articles And Supports Therefor (AREA)

Claims (8)

  1. Feuille absorbante monocouche ou multicouches dotée d'ondulations primaires (40) s'étendant le long d'un axe d'ondulation principal de ladite feuille, lesdites ondulations primaires (40) étant latéralement espacées d'une distance S (58, 60, 62), ladite feuille absorbante monocouche ou multicouches étant dotée d'un motif gaufré comprenant une pluralité d'éléments de design (90, 92, 94), de telle sorte que jusqu'à 50 % de la superficie de ladite feuille absorbante est gaufrée, caractérisée en ce que chaque élément de design dudit motif gaufré (52, 54) présente une largeur latérale caractéristique d'élément gaufré W (66), et une longueur caractéristique d'élément gaufré L (68), le long d'une direction L' et dans laquelle les éléments gaufrés sont espacés les uns des autres d'une distance D, et dans laquelle l'un au moins des rapports W:S et D:S est de 1 à 4.
  2. Feuille absorbante monocouche ou multicouches selon la revendication 1, dans laquelle W:S est de 1 à 4.
  3. Feuille absorbante monocouche ou multicouches selon l'une quelconque des revendications précédentes, dans laquelle ladite feuille est dotée d'ondulations secondaires (42) sensiblement perpendiculaires auxdites ondulations primaires (40), de telle sorte que ladite feuille est une feuille à ondulations biaxiales avec des ondulations secondaires (42) s'étendant le long d'un axe d'ondulation secondaire de ladite feuille.
  4. Procédé pour produire une feuille absorbante multicouches, comprenant :
    la préparation d'une pluralité de couches absorbantes (152, 156, 182, 190) comprenant au moins une couche à ondulations biaxiales, et
    le collage desdites couches (152, 156, 182, 190) les unes aux autres,
    dans lequel ladite couche à ondulations biaxiales inclut une pluralité d'ondulations primaires (40) s'étendant le long d'un axe d'ondulation principal de la feuille, lesdites ondulations étant espacées d'une distance S (74, 76, 78) ; et
    la réalisation d'un motif gaufré (52, 54) sur ladite feuille,
    dans lequel ledit motif gaufré comprend une pluralité d'éléments de design (50, 90, 92, 94) tels que jusqu'à 50 % de ladite superficie est gaufrée, caractérisé en ce que lesdits éléments de design (50, 90, 92, 94) ont une largeur caractéristique d'éléments de design W (66) et une longueur caractéristique de gaufrage L (68), le long d'une direction L' (70), et dans lequel le rapport W:S pour chaque élément de design est de 1 à 4.
  5. Procédé de fabrication d'une feuille absorbante monocouche, comprenant :
    la préparation d'une nappe (20) comprenant une pâte cellulosique ;
    le séchage de la nappe (20) pour former ladite feuille absorbante (20) ;
    la réalisation sur ladite feuille (20) d'ondulations primaires s'étendant le long d'un axe d'ondulation principal de la feuille absorbante, lesdites ondulations étant espacées d'une distance S (58, 60, 62) ; et
    le gaufrage de la feuille avec un motif gaufré comprenant une pluralité d'éléments de design (50, 90, 92, 94) tels que jusqu'à 50% de la superficie de ladite feuille est gaufrée, caractérisé en ce que chaque élément de design (50, 90, 92, 94) dudit motif gaufré a une largeur caractéristique d'élément gaufré W (66) et une longueur caractéristique de gaufrage L (68), le long d'une direction L' (70), et dans lequel le rapport W:S pour chaque élément de design est de 1 à 4.
  6. Procédé de fabrication d'une feuille absorbante gaufrée monocouche selon la revendication 5, ou de fourniture d'une couche absorbante dans un produit absorbant multicouches selon la revendication 4, ledit procédé comprenant :
    la préparation d'une nappe (20) comprenant une pâte cellulosique,
    l'application de ladite nappe (20) dans un séchoir de type yankee (22) ;
    le crêpage de ladite nappe (20) sortant dudit séchoir de type yankee avec une lame de crêpage ondulatoire (24) à une consistance entre 40 et 98%, de telle sorte que ladite feuille (20) ou ladite couche crêpée est dotée de nervures de crêpage (39) s'étendant latéralement dans la direction transversale (96, 98, 100) et d'ondulations (40, 82, 84, 86) s'étendant longitudinalement dans la direction de la machine, lesdites ondulations (40) étant espacées d'une distance S (58, 60, 62) ;
    le gaufrage de ladite feuille ou de ladite couche avec un motif gaufré comprenant une pluralité d'éléments de design (90, 92, 94, 50) tels que jusqu'à 50 % de la superficie de ladite feuille ou de ladite couche absorbante est gaufrée, caractérisé en ce que chaque élément de design dudit motif gaufré a une largeur latérale caractéristique d'élément gaufré W (66), et dans lequel le rapport W:S pour chaque élément de design (50, 90, 92, 94) est de 1 à 4 ; et
    si désiré, l'incorporation de ladite couche dans ledit produit absorbant multicouches (152, 154, 182, 190).
  7. Procédé selon l'une quelconque des revendications 4 à 6, dans lequel ladite pâte cellulosique comprend des fibres synthétiques.
  8. Procédé selon l'une quelconque des revendications 4 à 7, dans lequel ladite pâte cellulosique comprend un matériau non cellulosique.
EP00310059A 1999-11-12 2000-11-13 Produit papetier absorbant gaufré mono- ou multi-couche Revoked EP1099539B1 (fr)

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US709185 1991-06-03
US16508099P 1999-11-12 1999-11-12
US16527099P 1999-11-12 1999-11-12
US165080P 1999-11-12
US165270P 1999-11-12
US09/709,139 US6348131B1 (en) 1999-11-12 2000-11-09 Multi-ply embossed absorbent paper products
US709139 2000-11-09
US09/709,185 US6455129B1 (en) 1999-11-12 2000-11-09 Single-ply embossed absorbent paper products

Publications (2)

Publication Number Publication Date
EP1099539A1 EP1099539A1 (fr) 2001-05-16
EP1099539B1 true EP1099539B1 (fr) 2007-03-28

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AT (1) ATE358016T1 (fr)
DE (1) DE60034098T2 (fr)
ES (1) ES2281325T3 (fr)

Cited By (1)

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US7857941B2 (en) 2001-12-21 2010-12-28 Georgia-Pacific Consumer Products Lp Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength

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US7037406B2 (en) 1999-11-12 2006-05-02 Fort James Corporation Cross-machine direction embossing of absorbent paper products having an undulatory structure including ridges extending in the machine direction
US7235156B2 (en) * 2001-11-27 2007-06-26 Kimberly-Clark Worldwide, Inc. Method for reducing nesting in paper products and paper products formed therefrom
US8753737B2 (en) 2009-05-19 2014-06-17 The Procter & Gamble Company Multi-ply fibrous structures and methods for making same
US9243368B2 (en) 2009-05-19 2016-01-26 The Procter & Gamble Company Embossed fibrous structures and methods for making same
US20100297378A1 (en) * 2009-05-19 2010-11-25 Andre Mellin Patterned fibrous structures and methods for making same
WO2021126026A1 (fr) * 2019-12-18 2021-06-24 Essity Hygiene And Health Aktiebolag Produit en papier et procédé et son appareil de fabrication

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CA2069193C (fr) * 1991-06-19 1996-01-09 David M. Rasch Papier de soie portant de grands motifs decoratifs et appareil de fabrication utilise pour ce faire
US5690788A (en) * 1994-10-11 1997-11-25 James River Corporation Of Virginia Biaxially undulatory tissue and creping process using undulatory blade
FR2728152B1 (fr) * 1994-12-16 1997-01-24 Kaysersberg Sa Papier absorbant gaufre a motifs combines
CA2204452C (fr) * 1996-05-09 2007-03-27 Joseph C. Leege Methode de fabrication de papier ultra-doux a masse surfacique elevee et produit ainsi obtenu

Cited By (2)

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Publication number Priority date Publication date Assignee Title
US8142617B2 (en) 1999-11-12 2012-03-27 Georgia-Pacific Consumer Products Lp Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength
US7857941B2 (en) 2001-12-21 2010-12-28 Georgia-Pacific Consumer Products Lp Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength

Also Published As

Publication number Publication date
DE60034098T2 (de) 2007-12-13
DE60034098D1 (de) 2007-05-10
ES2281325T3 (es) 2007-10-01
EP1099539A1 (fr) 2001-05-16
ATE358016T1 (de) 2007-04-15

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