WO2012123020A1 - Fibrous product and method for manufacturing such a fibrous product - Google Patents
Fibrous product and method for manufacturing such a fibrous product Download PDFInfo
- Publication number
- WO2012123020A1 WO2012123020A1 PCT/EP2011/053846 EP2011053846W WO2012123020A1 WO 2012123020 A1 WO2012123020 A1 WO 2012123020A1 EP 2011053846 W EP2011053846 W EP 2011053846W WO 2012123020 A1 WO2012123020 A1 WO 2012123020A1
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- WO
- WIPO (PCT)
- Prior art keywords
- ply
- embossing
- roll
- protuberances
- embossed
- Prior art date
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Classifications
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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
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/263—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer having non-uniform thickness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/08—Corrugated paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/06—Embossing
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/002—Tissue paper; Absorbent paper
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
- D21H27/40—Multi-ply at least one of the sheets being non-planar, e.g. crêped
-
- 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
- B31F2201/0725—Hardness
-
- 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
-
- 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
- B31F2201/0764—Multi-layered the layers being nested
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1039—Surface deformation only of sandwich or lamina [e.g., embossed panels]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
Definitions
- the invention relates to a fibrous product, especially tissue paper product, non-woven product or a hybrid thereof, and preferably hygiene and cleaning product.
- the invention also relates to a method for producing such a fibrous product.
- Hygiene or wiping products primarily include all kinds of dry-creped tissue paper, wet-creped paper, TAD-paper (Through Air Drying) and cellulose or pulp-wadding or all kinds of non-wovens, or combinations, laminates or mixtures thereof.
- Typical properties of these hygiene and wiping products include the reliability to absorb tensile stress energy, their drapability, good textile-like flexibility, properties which are frequently referred to as bulk softness, a higher surface softness and a high specific volume with a
- a liquid absorbency as high as possible and, depending on the application, a suitable wet and dry strength as well as an appealable visual appearance of the outer product's surface are desired.
- these hygiene and wiping products allow these hygiene and wiping products to be used, for example, as cleaning wipes such as paper or non-woven wipes, windscreen cleaning wipes,
- the hygiene and wiping products can be dry, moist, wet, printed or pretreated in any manner.
- the hygiene and wiping products may be folded, interleaved or individually placed, stacked or rolled, connected or not, in any suitable manner. Due to the above description, the products can be used for personal and household use as well as commercial and
- tissue paper is to be made out of pulp
- the process essentially comprises a forming that includes a box and a forming wire portion, and a drying portion (either through air drying or conventional drying on a yankee cylinder) .
- the production process also usually includes the crepe process essential for tissues and, finally, typically a monitoring and winding area.
- Paper can be formed by placing the fibers, in an oriented or random manner, on one or between two continuously revolving wires of a paper making machine while simultaneously removing the main quantity of water of dilution until dry-solids contents of usually between 12 and 35% are obtained. Drying the formed primary fibrous web occurs in one or more steps by mechanical and thermal means until a final
- the conventional dry crepe process involves creping on a usually 4.0 to 6.5 m diameter drying cylinder, the so-called yankee cylinder, by means of a crepe doctor with the
- TAD Through Air Drying
- primary fibrous web that leaves the forming and sheet making stage is pre-dried to a dry-solids content of about 80% before final contact drying on the yankee cylinder by blowing hot air through the fibrous web.
- the fibrous web is supported by an air-permeable wire or belt or TAD-fabric and during its transport is guided over the surface of an
- TAD-cylinder Structuring the supporting wire or belt makes it possible to produce any pattern of compressed zones broken up by deformation in the moist state, also named moulding, resulting in increased mean specific volumes and consequently leading to an increase of bulk softness without decisively decreasing the strength of the fibrous web.
- processing machines which include operations such as unwinding the base tissue, repeated smoothing of the tissue, printing, embossing, to an extent combined with full area and/or local application of adhesive to produce ply adhesion of the individual plies to be combined together as well as longitudinal cut, folding, cross cut, placement and bringing together a plurality of
- Such processing steps may also include application of substances like scents, lotions, softeners or other chemical additives.
- the individual paper ply webs can also be pre-embossed and then combined in a nip of rolls according to the embossing methods known in the art. Any embossing can lead to embossed elements all having the same height or to embossing elements having different heights.
- Ply bonding e.g. by mechanical or by chemical means are other well-known methods mainly used for hankies, napkins and bathroom tissues and household towels.
- a well-known technique to increase the thickness of a paper product is to emboss the paper web.
- An embossing process is carried out in the nip between an embossing roll and an anvil roll.
- the embossing roll can have protrusions on its
- depressions in the paper web or it can have depressions in its circumferential surface leading to so-called embossed protrusions in the paper web.
- Anvil rolls may be softer than the corresponding embossing roll and may consist of rubber, such as natural rubber, or plastic materials, paper or steel.
- a first web is directed through the nip between an embossing roll and an anvil roll. In this nip the web is provided with an embossing pattern. Thereafter, an application roll for adhesive applies adhesive to those parts of the first web at which there are protruding embossing elements in the
- the adhesive is transported from an adhesive bath via an adhesive transfer roll to the application roll.
- ⁇ second web is transported to the first web and adhesively bonded to the first web in the nip between the so-called marrying roll and the embossing roll.
- the adhesive bonding takes place at those portions at which the adhesive was applied.
- the second manufacturing method (DBSL/Nested) is very similar to the above-described Goffra Incolla method. It comprises an additional pair of rolls consisting of a second embossing roll and a second anvil roll. The additional pair of rolls serves to emboss the second web before it is adhesively bonded to the first web using the marrying roll. Typically, the additional pair of rolls is placed close to the first pair of rolls and the marrying roll. Especially when using the so-called Nested-method such close arrangement is important.
- the Nested-method can be considered as a special case of the general DESL-manufacturing method. For the
- the embossing elements of the first embossing roll and the embossing elements of the second embossing roll are arranged such that the embossed elements of the first embossed ply and the embossed elements of the second embossed ply fit into each other similar to a gearing system. This serves to achieve a mutual stabilization of the two plies.
- the DESL manufacturing method such correlation between the embossed elements of the first, upper ply and the second, lower ply, does not have to apply. Nevertheless, in a literature the term DESL is often used synonymous to a Nested-method.
- the third manufacturing method (Pin-to-Pin/Foot-to-Foot) is similar to the DESL method.
- both the tipper ply and the lower ply are embossed, respectively.
- Adhesive is applied onto the embossed
- the ply bonding is not achieved by means of a marrying roll as in the DBSL method but is achieved directly by means of the protruding embossing elements of the second embossing roll.
- an exact adjustment of the width of the gap between the first embossing roll and the second embossing roll is required, which is mainly defined by the individual thickness of both webs (upper ply and lower ply) .
- the embossing rolls have to be designed such that at least some of the protruding embossing elements of both rolls face each other. This is the reason why the terminology
- Pin-to-Pin or Foot-to-Foot embossing is used.
- the first embossing roll is formed of a hard material, usually metal, especially steel, but there are also known embossing rolls made of hard rubber or hard plastics materials.
- the embossing rolls can be a male roll having individual protrusions.
- the embossing roll can be a female roll with individual embossing depressions. Typical depths of the engraved embossing patterns are between 0.4mm and 2.0mm.
- the anvil roll typically has a rubber coating.
- structurized anvil rolls especially rolls made of paper, rubber or plastics materials or steel are also known.
- the applicator roll for adhesive is usually also a rubber roll with a plain smooth circumferential surface, wherein the hardness of the rubber coating is between the hardness of the anvil roll and the hardness of the marrying roll. Commonly used values for the hardness of the rubber coating are 70 to 85 Shore A. When selecting the rubber material its
- the application system for adhesive consisting of applicator roll, adhesive transfer roll and adhesive bath can be
- Application rolls may be structured rolls.
- adhesive transfer rolls have become known having defined pit-shaped depressions in their circumferential surface. Such adhesive transfer rolls are known as
- anilox-rolls Such roll is usually made of ceramic material or it is a roll made of steel or copper and coated with chromium. Excessive adhesive is removed from the surface of the anilox-roll by means of a blade. The amount of adhesive is determined by the volume and the number of depressions. Alternative application systems for applying adhesives are based on a spraying equipment.
- a second possibility to influence the amount of adhesive transferred is the adjustment of the difference in
- the adhesive bath can be designed as a simple trough, application systems with a blade can also be designed as chamber systems.
- marrying roll commonly has a smooth rubber surface with a hardness of about 80-98 Shore A.
- a suitable material is e.g. NBR (acrylnitrile-butadien rubber) .
- marrying rolls also have become known which, in addition to the rubber coating, are provided with a steel coating. Such steel coating is often provided in form of a steel band spirally wound onto the rubber coating as described in WO2004/065113.
- micro-pre-embossing device In case that the single layers individually or together are pre-embossed, a so-called micro-pre-embossing device is used. Such pre-embossing device is often used in combination with the Goffra Incolla technology. Also commonly used is a printing onto the tissue product before or after the ply bonding step. Also known are variants including the
- Another well-known embossing technique comprises a steel embossing roll and a corresponding anvil steel roll
- Matched Steel Embossing or a steel roll and a corresponding flat anvil steel roll (so-called pin to flat) or a steel roll and a corresponding anvil rubber roll with embedded steel elements e.g. in a spiral shape.
- the embossing not only serves to provide bulk to the fibrous product but also to provide an improved optical appearance to the product.
- the optical appearance of a product is
- the optical appearance can be improved by combining embossing and
- Another reason for embossing is to generate higher absorbency or improved perceived softness.
- a multi-ply sheet with a stable thickness is obtained, because the bottom embossing matches to the top embossing and stabilizes the whole sheet.
- the drawback of the nested configuration is smaller handfeel levels compared to other embossing configurations.
- Goffra Incolla the same applies receive
- WO 02/103112 Al suggests a three-ply tissue paper product with a micro-embossed top ply, a micro-embossed bottom ply and a middle ply sandwiched between the top ply and the bottom ply and being provided with a macro-embossed pattern. All three plies are ply bonded together after the top ply, the bottom ply and the middle ply have been
- the outer plies and the middle ply are ply bonded together in a non-registered manner.
- WO 2006/136186 Al describes a multi-ply web of tissue paper wherein a first ply is provided with an embossing pattern forming cushions limited by regions of compressed material.
- the second web is provided with a second embossing pattern with protrusions of compressed material. The first web and the second web are combined together such that the
- protrusions of compressed material of the second web are positioned inside the cushions of the first web. This serves to provide multi-ply tissue paper with high absorption, softeness and bulk thickness to provide a good feeling to the user.
- the inventive fibrous product is especially a tissue paper product, non-woven product or a hybrid thereof, and
- the inventive fibrous product comprises at least one top ply, at least one middle ply and at least one bottom ply.
- the term "at least one" should indicate that top ply, middle ply and bottom ply can in themselves be a multi-ply structure, respectively. However, if e.g. a double-ply bottom ply is used, such plies are not processed separately when embossing and bonding together the inventive fibrous product.
- these plies are made up of more than one fibrous ply.
- the top ply is provided with an embossing pattern and the middle ply is embossed in register with the top ply so that second embossing protuberances of the middle ply nest into pillow-like chambers between first embossing protuberances of the top ply.
- the second embossing protuberances of the middle ply need not to be shaped such as to fill to a large extent the pillow-like chamber of the top ply.
- the inventive product is further provided with a bottom ply which is bonded to both the top ply and the middle ply. This bottom ply is also in register with the top ply and middle ply and closes the pillow-like chambers of the top ply to form closed cushions in the product.
- Such fibrous product optimizes bulk and three dimensional optics but still has a high level of handfeel. Unlike nested configurations in the prior art, it is not the bottom ply which nests into the top ply, but a middle ply.
- the at least one bottom ply comprises non-embossed areas and embossed areas whereby the non-embossed areas are in register with the top ply and the middle ply.
- the fibrous products are unembossed at the bonding regions at which the at least one bottom ply is bonded to both the at least one top ply and the at least one middle ply. At the bonding regions at which ply bonding is realized, the optical appearance of an
- embossed pattern can be of inferior quality. However, if such bonding regions are placed in the non-embossed areas of the at least one bottom ply, a high optical quality of the product can be maintained.
- the provision of non-embossed areas has further advantages. Such non-embossed areas might be shaped according to a desired motive pattern and could even be used to reflect the design on the at least one top ply down to the bottom ply. In other words, the embossed pattern of the top ply could essentially correspond to the non-embossed areas of the bottom ply. ⁇ further advantage is the increased softness of the product depending on the fraction of non-embossed areas relative to the embossed areas.
- the at least one bottom ply is preferably not made from TAD-paper, although this is technically not
- the bottom ply is in register with the nested structure consisting of top ply and middle ply so that the proper orientation of the pattern of non-embossed areas relative to the embossing of the middle ply and the top ply is realized.
- This serves to create a good optical appearance of the product.
- a further advantage of the product is its reversibility or two-sidedness, which means that both sides can be made clearly different in view of their embossing pattern and can independently be either the top ply or the bottom ply.
- top ply and bottom ply only serve to define the product as such without limiting the product with regard to the direction in which it can be wound up to a roll or which side is used by a user.
- the top ply can be structured with relatively large pillow-like chambers delimited by embossing protuberances to increase its
- the embossed areas of the at least one bottom ply can be provided with a micro-embossing pattern or any other kind of a conventional pre-embossing pattern.
- the non-embossed areas are of an elongate shape having a width between 0.1 and 30mm, preferably between 0.1 and 20mm and most preferably between 0.1 and 15mm.
- the elongate shape may be a linear shape.
- protuberances on the top ply are, there can be unembossed areas in the bottom ply. This makes it possible to reflect the motive elements embossed in the top ply onto the bottom surface.
- a preferred embodiment of the inventive fibrous product uses a bottom ply further comprising one or more second non-embossed areas.
- the second non-embossed areas can be freely selected according to functional and aesthetic characteristics. The aesthetic characteristics follow from the position and shape of the second non-embossed areas, whereas the functional characteristics are closely related to the increased softness of the product in the non-embossed areas which can be arranged and sized so as to arrive at a desired perceived overall softness.
- the ratio between the non-embossed areas is the ratio between the non-embossed areas
- the second non-embossed areas and the embossed areas ranges of the bottom ply between 5% and 70%, preferably between 10% and 60%, especially 15% to 50% for the non- embossed areas and 30% to 95%, preferably 40% to 95% and especially 50% to 85% for the embossed areas. Such ranges lead to a good functional behaviour of the product without compromising the desired appealing optical effect.
- the at least one bottom ply is a two-ply structure and both bottom plies are bonded together by means of mechanical ply bonding, e.g. by
- edge-embossing or by knurling which provides a local ply bonding of the bottom plies.
- Ply-bonding can also be achieved by lamination using adhesives, e.g. hot melts, or by using process such as nested or spot-embossing techniques.
- the top ply, the middle ply and the bottom ply are adhesively bonded together at the bonding regions which are the common bonding positions.
- the wickability of the fibrous product sheets can be used so that the adhesive is applied to one side of the middle ply and penetrates through the middle ply so that one specific spot can used to bond together all three plies. If the top ply, the middle ply or the bottom ply are provided with more than one ply, the same basic principle applies.
- the first embossing protuberances of the at least one top ply comprise linear or dotted protuberances essentially delimiting pillow-like chambers with a surface area between 0.2cm 2 and 3cm 2 ' preferably between 0.25cm 2 and 2cm 2 and most preferably between 0.3cm 2 and 1cm 2 .
- This embossing pattern forms cushions which are surrounded by regions of compressed material.
- linear protuberances should indicate that such protuberances have an elongated shape, especially are straight or curved lines.
- Such an elongated shape has a width of from 0.1 to 10mm, preferably from 0.1 to 6mm and most preferably from 0.1 to 4mm, and the width may vary along the elongation.
- the provision of such linear protuberances has the advantage that the cushions formed by the pillow-like chambers are surrounded by compressed zones, the area of which can be minimized.
- Such linear protuberances can fully circumvent the pillow-like chambers, however, it is preferred to provide linear protuberances which do not fully surround each pillow-like chamber.
- the term "dotted protuberances" should indicate that such protuberances have a shape of interrupted lines or a shape of small individual points or spots. This measure is advantageous in order to maintain the softeness of the product and has the further technical effect that during embossing, trapped air can escape.
- the regions of compressed material can also have the shape of individual dots positioned in linear arrangements.
- the regions of compressed material could form individual elongated sections being positioned together to form the appearance of dashed lines.
- the pillow-like chambers of the at least one top ply are
- the second protuberances of the at least one middle ply having a cross-sectional area at their top of between 0.2cm 2 and 0.8cm 2 . If relatively large pillow-like chambers are provided, the protuberances of the middle ply nesting into the pillow-like chambers of the top ply serve to stabilize the pillow-like chambers. Pillow-like chambers of a big size tend to collapse and lose shape when rolling the web. Therefore, in order to keep the desired cushion
- these pillow-like chambers are stabilized by filling them with the second protuberances of the at least one middle ply.
- different alternatives are
- each pillow-like chamber could only be filled by one single second protuberance of the middle ply.
- the pillow-like chambers are at least
- Such functional substances can be selected according to the desired field of application of the fibrous product and its desired reversibility. Further, such functional substances have the further effect to provide an
- inventive fibrous product faces the at least one top ply.
- inventive fibrous product such functional substances may be mixed with colours.
- the inventive fibrous product is further characterized by a two-sidedness which is visible to the consumer.
- the embossed areas of the bottom ply of the fibrous product comprise embossed protuberances which project in a direction away from the at least one middle ply.
- the embossed protuberances project outwardly of the product.
- a harder bottom surface might be suitable to provide a product with a two- sidedness with a soft absorbing top surface and a harder bottom surface.
- the preferred orientation of the embossed protuberances to the outside of the product improves the visual distinction between the embossed areas and the non-embossed areas of the bottom ply.
- the embossed areas of the bottom ply of the fibrous product may also comprise protuberances which project in a direction towards the at least one middle ply.
- the embossed protuberances project inwardly of the product. This makes the bottom surface softer than in case that the embossing protuberances would be directed to the outside of the product.
- the method for producing an inventive fibrous product comprises the steps of: directing the at least one top ply into the nip of a first embossing station with a first embossing roll and a first counter-roll; directing the at least one middle ply into the nip of a second embossing station with a second embossing roll and a second counter-roll, wherein the second embossing roll is synchronized with the first embossing roll; generating a subunit by combining on the first embossing roll the at least one top ply and the at least one middle ply such that the second embossing protuberances of the at least one middle ply nest into pillow-like chambers formed between the first embossing
- protuberances of the at least one top ply applying adhesive to the subunit at the surface of the at least one middle ply; directing the at least one bottom ply into the nip of a third embossing station with a third embossing roll and a third counter roll; wherein the third embossing roll is synchronized with the first embossing roll and second embossing roll; and combining the subunit and the at least one bottom ply in the nip between the first embossing roll and a marrying roll.
- the adhesive is applied to the middle ply where it faces the at least one bottom ply. Further, the adhesive is mainly applied to the highest projections of the first embossing roll which correspond to the first protuberances at least partially surrounding the pillow-like chambers.
- the adhesive penetrates the at least one middle ply and effects adhesive ply bonding between top ply, middle ply and bottom ply at the same positions.
- the synchronized operation of the three embossing stations makes it possible to place the second protuberances inside the pillow-like chambers at least partially surrounded by the first protuberances.
- the bonding areas are placed into the non-embossed areas of the bottom ply.
- the second counter roll is preferably a steel roll.
- a steel/steel embossing according to a so-called Matched Steel Embossing can be used to increase the stabilizing effect of the second embossing protuberances in that they are higher compressed than in case of a steel/rubber embossing station which gives rise to a better stabilizing effect of the second embossing protuberances within the pillow-like chambers of the at least one top ply.
- the method further comprises the step of applying a functional agent to the at least one middle ply before embossing the at least one middle ply.
- a functional agent can be brought to that surface of the middle ply which, in the inventive fibrous product, faces the top ply so that the functional agent at least partially fills the pillow-like chambers formed between top ply and middle ply.
- the method further comprises the step of applying colour to the at least one middle ply before generating the subunit by combining top ply and middle ply.
- colour on the middle ply shining through the fibrous product can be used to improve the aesthetic appearance of the product.
- the colour is applied toward the at least one middle ply on the second embossing station. This leads to coloured top surfaces of the second protuberances.
- the device for manufacturing an inventive fibrous product comprises a first embossing station with a first embossing roll and a first anvil roll, a second embossing station with a second embossing roll and a second anvil roll, the second anvil roll being a rubber roll or a steel roll, a glueing deck with an applicator roll running against the first embossing roll, a third embossing station comprising a third embossing roll and a third anvil, and a marrying roll running against the first embossing roll.
- the first embossing roll, second embossing roll and third embossing roll are adapted to run in register.
- the first embossing station and second embossing station have to run in register such that the positional relationship of the first embossing protuberances and the second embossing protuberances can be predetermined in the final product.
- the third embossing roll is also in register with the first (and second) embossing roll, so that the non-embossed areas of the bottom ply are in register with the top ply and the middle ply.
- the device further comprises an application deck with a second applicator roll positioned upstream of the second embossing station.
- Such application deck can be used to apply functional agents to the at least one middle ply.
- Fig. 1 is a cross-sectional view of a web according to one embodiment of the invention
- Fig. 2 schematically shows a device for manufacturing an inventive fibrous product
- Fig. 3a shows a section of the surface of the first
- Fig. 3b shows the corresponding section as given in Fig. 3a but on the surface of the second embossing roll; and Fig. 3c shows a superposition of both surfaces of the
- Fig. 1 shows an example of an inventive fibrous product generally denoted by reference numeral 10. It consists of a top ply 12, a middle ply 14 and a bottom ply 16. Top ply, middle ply or bottom ply could be multi-ply webs,
- Top ply 12 is provided with an embossing pattern forming first protuberances 18 which delimit pillow-like
- the first protuberances 18 are preferably of elongated shape, like lines which can be straight or curved and can even form closed geometries. However, it is
- the pillow-like chambers 20 are not fully surrounded by the first protuberances so that trapped air can escape in the course of the embossing process.
- top ply 12 can be provided with a
- micro-embossing pattern (not shown in Fig. 1) .
- micro-embossing should refer to a dot density of more than 30 dots per cm ⁇ .
- the at least one middle ply 14 is also embossed and is provided with second embossing protuberances 22 which are arranged and sized so as to nest into the pillow-like
- the second embossing protuberances have a cross-sectional size at their top of between 0.2cm 2 and 0.8cm 2 .
- protuberances can be selected freely among technically feasible shapes like protuberances with a top surface shaped as a triangle, square, circle or star just to give a few examples of basic geometries. Besides such simple geometries, more complex geometries specifically adapted to the shape of the pillow-like chambers can be selected as can be seen with reference to Fig. 3b showing the cross-sectional shape of the second embossing
- the second embossing protuberances serve to stabilize the pillow-like chambers so that pillow-like chambers of a considerable size can be realized while such large
- the chambers can be selected between 0.2cm 2 to 3cm 2 and preferably between 0.3cm 2 and 1cm 2 .
- the first embossing protuberances surrounding the pillow-like chambers have a thickness between 0.4 and 1mm and preferably between 0.4 and 0.8mm.
- the at least one bottom ply 16 is provided with embossed areas 25 and non-embossed areas 27.
- the embossed areas 25 can be provided with micro-embossed protrusions 29 which is schematically shown in Pig. 1.
- the bottom layer seals the fibrous product 10 in a way to finally form the pillow-like chambers 20 acting as cushions.
- the ply bonding between top ply 12, middle ply 14 and bottom ply 16 is achieved by means of adhesive at positions 24 which are within non-embossed areas 27.
- the three plies of the fibrous product are adhesively bonded together at identical positions.
- the non-embossed areas of the bottom ply can be of an elongate shape having a relatively small width which can be between 0.1mm and 30mm.
- the width ranges between 0.1 and 30mm, preferably between 0.1 and 20mm, and most preferably between 0.1 and 15mm. Since the bonding between the plies is at the position of the first protuberances 18 of the top ply, the non-embossed areas of the bottom ply follow the design provided by the position of the first embossing protrusions which essentially surround the cushions 20 of the first ply. In such a way, the embossing pattern of the top ply can be mirrored to the bottom ply with the difference that, at the bottom ply, the embossed parts of the top ply are the unerabossed areas.
- the bottom ply with second non-embossed areas separate to the above-described (first) non-embossed areas.
- Such second non-embossed areas can be freely selected to provide a special motive element.
- the second non-embossed areas can be selected to influence the functional behaviour of the bottom ply, namely to provide additional areas which are non-embossed and have a higher perceived smoothness.
- Another possibility to influence the behaviour of the bottom ply is the direction of the embossing protrusions. This can be directed to the inside of the three ply product as is schematically shown in Fig. 1. However, it is also possible to direct the embossing protrusions to the outside of the product so that the embossed
- protrusions of the top ply extend outwardly from the base surface layer of the bottom ply.
- the inventive fibrous product of Fig. 1 should preferably be manufactured by a process whereby the at least one top ply and the at least one middle ply are embossed in such a way that, when combining together top ply and middle ply, the second embossing protuberances of the at least one middle ply are accurately positioned at defined desired positions within the pillow-like chambers 20 formed in the at least one top ply.
- This requires an embossing process in which the at least one top ply and the at least one middle ply are embossed in a synchronized manner in order to safeguard the desired geometrical arrangement.
- the bottom ply is also synchronized to the top ply and middle ply.
- the three plies are bonded together at non-embossed areas of the bottom ply. This improves the aesthetical appearance of the bottom ply because the embossed protuberances are not flattened at specific positions. This would be the case if the plies were bonded together in embossed areas of the bottom ply.
- the plies might have a different base colour or the middle ply might be provided with colour at the top surfaces 26 of the second embossing protuberances.
- the pillow-like chambers might be at least partially filled with active agents like lotions, cleaning agents or hardening substances.
- Fig. 2 describes the process used for manufacturing product 10.
- the top ply 12 is optionally pre-embossed in a first pre-embossing station 28 and directed into the nip of a first embossing station consisting of a first
- embossing roll 30 and an anvil roll 32 are preferably made of metal especially steel, or hard plastics materials or hard rubber. In case of plastics, very hard plastic material is preferred, alternatively a resin material is also possible.
- the anvil roll is made of rubber like EPDM or NBR
- the at least one first ply 12 receives a first embossing pattern with first protuberances 18 as schematically shown in Fig. 1.
- the at least one middle ply 14 is introduced into the nip of a second embossing roll 34 and an anvil roll 36 which form a second embossing station.
- a second embossing roll 34 and anvil roll 36 which form a second embossing station.
- the same materials as described above with reference to the first embossing roll 30 and the first anvil roll 32 also apply.
- the second embossing station consisting of the second embossing roll 34 and the second anvil roll 36, the at least one middle ply 14 is provided with second
- the device can further be provided with an application device 38 including an applicator roll 38a for applying functional substances to the at least one middle ply 14.
- an application device 38 including an applicator roll 38a for applying functional substances to the at least one middle ply 14.
- Such applicator devices are well-known in the art and commonly used for the application of adhesives or coloured substances.
- the device might be provided with an application device 40 which runs against the second embossing roll 34 and applies a coloured substance toward the protrusions formed in the second embossing roll 34.
- the first embossing roll 30 and the second embossing roll 34 are operated in register which means that both rolls have to be operated in a synchronized manner such that the embossed middle ply 14 leaving the second embossing roll 34 can be directed in a predetermined positional
- the next method step is carried out at the glueing deck 42 including a glue applicator roll 42a running against the first embossing roll 30. In this conventional glueing deck 42, adhesive is applied. For laminating together the single webs of material,
- Suitable adhesives are, inter alia, glue on the basis of starch or modified starch like for example methyl cellulose or carboxylized methyl cellulose and adhesively acting polymers on the basis of synthetic resins, caoutchouc, polypropylene,
- adhesives can also contain colouring agents in order to improve the optical appearance of the finished products.
- water based glues are used for laminating together paper layers.
- An option to increase the visibility or to enhance the visible appearance of the product is to provide coloured adhesive.
- a marrying roll 44 runs against the first embossing roll 30 such that the subunit consisting of the at least one top ply 12, the at least one middle ply 14 and the glue applied to a part of the surface of the at least one middle ply can be brought in contact with bottom ply 16 which is laminated to the middle ply in the nip between the first embossing roll 30 and the marrying roll 44.
- Ply bonding between the at least one middle ply and the at least one top ply is achieved such that part of the adhesive applied in glueing deck 42 penetrates the at least one middle ply due to its wicking capability and effects ply bonding between middle ply and top ply as well.
- the bottom ply 16 is embossed in the nip between the third embossing roll 46 and the corresponding anvil roll 47 which form a third embossing station.
- the same materials as described above with reference to the first embossing roll 30 and the first anvil roll 32 also apply.
- the third embossing station consisting of the third embossing roll 46 and the third anvil roll 47, the at least one bottom ply 16 is provided with third embossing protuberances as schematically shown in Fig. 1.
- the surface of the embossing roll is shaped such that it generates an embossing pattern on the at least one bottom ply 16 consisting of embossed areas 25 and non-embossed areas 27 (see Fig. 1) .
- product lOis characterized by the fact that all bonding positions 24 at which the three plies are bonded together are situated in non-embossed areas of the at least one bottom ply 16. Due to this fact the third embossing roll 46 also runs in register with the first embossing roll 30 and second embossing roll 34. After leaving the embossing station, the at least one bottom ply 16 is directed into the nip between the first embossing roll 30 and the marrying roll 44 where the three plies are bonded together.
- Fig. 3a gives one specific example of part of the embossing surface of an embossing roll 30 for embossing the at least one top ply.
- the embossing roll is provided with numerous linear protrusions 50 which are curved and have a varying thickness like the linear protrusion 50a given as an example.
- the linear protrusions 50 on the embossing surface of the first embossing roll 30 serve to form linear embossing protuberances in the at least one top ply which surround pillow-like chambers like those exemplified by reference numeral 20 as used in Fig.
- Such pillow-like chambers 20 have a considerable size as can be seen from the pattern as shown in Fig. 3a which can be considered to show the size of such chambers on a 1:1 scale.
- Fig. 3b shows part of the surface of the second embossing roll 34 for embossing the at least one middle ply.
- the frame as shown in Fig. 3b corresponds to that as shown in Fig. 3a which becomes apparent from Fig. 3c which shows a
- Figs. 3a and 3b Such superposition is possible since the first embossing roll 30 and the second embossing roll 34 are running in register.
- the surface of the roll is provided with protrusions 52 which can have very different cross-sectional shapes as can be seen from Fig. 3b.
- the protrusions 52 generate the second embossing protuberances 22 of the at least one middle ply which nest into the pillow-like chambers 20 of the at least one top ply.
- the second embossing protuberances and, correspondingly, the protrusions 52 on the second embossing roll are arranged such as to stabilize the pillow-like chambers 20, which follows from Fig. 3c showing a
- Fig. 3c is an artificial drawing because there is no surface of an embossing roll having both the embossing protrusions 50 and 52. Therefore, Fig. 3c might be better interpreted as the schematic view onto the top surface of an inventive fibrous product 10 showing pillow-like chambers 20 as well as coloured second embossing protuberances 22 shining through.
- the first embossing protuberances 18 are represented by black lines in order to increase the visibility of the graphic representation according to Fig. 3c. To some extent, the first embossing protuberances 18 could be made more visible by using coloured adhesive for the ply bonding of the three plies which is carried out along the first embossing protuberances 18.
- single pillow-like chambers can be either stabilized by a single second
- embossing protrusion like exemplified by reference numeral 22a or by a plurality of second embossing protuberances like exemplified by the second embossing protuberances 22b, 22c.
- the inventive product combines a high mechanical strength with good handfeel values and an improved bulk.
- the pillowlike chambers are both visible and contribute to the overall haptic appearance of the product.
- the product has a high reversibility which is especially useful in case of its use as a household tissue which can be provided with a micro- embossed polishing side corresponding to the at least one bottom layer and an opposite side which can be used for scrubbing with active chambers filled with lotions or washing substances provided inside the pillow-like chambers.
- the inventive product has a good optical appearance and the design as shown on the top ply can also be repeated on the bottom ply but in a reverse manner so that the embossed protuberances of the top ply may correspond to a non- embossed linear shape of the bottom ply.
- the aesthetical appearance of the bottom ply can be further improved.
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- Engineering & Computer Science (AREA)
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Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP11708256.0A EP2686164B1 (en) | 2011-03-15 | 2011-03-15 | Fibrous product and method for manufacturing such a fibrous product |
US14/004,425 US20130344294A1 (en) | 2011-03-15 | 2011-03-15 | Fibrous product and method for manufacturing such a fibrous product |
PCT/EP2011/053846 WO2012123020A1 (en) | 2011-03-15 | 2011-03-15 | Fibrous product and method for manufacturing such a fibrous product |
BR112013023526A BR112013023526A2 (en) | 2011-03-15 | 2011-03-15 | fibrous product for the manufacture of such fibrous product |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/EP2011/053846 WO2012123020A1 (en) | 2011-03-15 | 2011-03-15 | Fibrous product and method for manufacturing such a fibrous product |
Publications (1)
Publication Number | Publication Date |
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WO2012123020A1 true WO2012123020A1 (en) | 2012-09-20 |
Family
ID=43901172
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/EP2011/053846 WO2012123020A1 (en) | 2011-03-15 | 2011-03-15 | Fibrous product and method for manufacturing such a fibrous product |
Country Status (4)
Country | Link |
---|---|
US (1) | US20130344294A1 (en) |
EP (1) | EP2686164B1 (en) |
BR (1) | BR112013023526A2 (en) |
WO (1) | WO2012123020A1 (en) |
Cited By (1)
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CN107002350A (en) * | 2014-10-17 | 2017-08-01 | 森织汽车内饰公司 | The dimension enhancing of artificial leather compound polyurethane material |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
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ES2533841T3 (en) * | 2012-05-14 | 2015-04-15 | Sca Tissue France | Hybrid multilayer tissue paper product and method of manufacturing it |
US9416496B2 (en) | 2013-10-16 | 2016-08-16 | Georgia-Pacific Consumer Products Lp | Method for reducing the bulk and increasing the density of a tissue product |
USD765424S1 (en) * | 2014-09-30 | 2016-09-06 | Kimberly-Clark Worldwide, Inc. | Non-woven material |
JP6480882B2 (en) * | 2016-03-22 | 2019-03-13 | 角田紙業株式会社 | Laminated paper, laminated paper manufacturing method, and laminated paper manufacturing apparatus |
US10654244B2 (en) | 2016-10-14 | 2020-05-19 | Gpcp Ip Holdings Llc | Laminated multi-ply tissue products with improved softness and ply bonding |
TWI766955B (en) * | 2017-03-02 | 2022-06-11 | 日商大王製紙股份有限公司 | sanitary tissue paper |
EP3646765A4 (en) * | 2017-06-30 | 2021-03-10 | Daio Paper Corporation | Toilet paper |
CN110753508B (en) * | 2017-06-30 | 2022-04-19 | 大王制纸株式会社 | Toilet paper |
WO2020121013A1 (en) * | 2018-12-13 | 2020-06-18 | Essity Hygiene And Health Aktiebolag | Tissue product and method and apparatus for producing same |
JP6955596B2 (en) * | 2019-02-08 | 2021-10-27 | 角田紙業株式会社 | Laminated paper manufacturing equipment and laminated paper manufacturing method |
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2011
- 2011-03-15 WO PCT/EP2011/053846 patent/WO2012123020A1/en active Application Filing
- 2011-03-15 US US14/004,425 patent/US20130344294A1/en not_active Abandoned
- 2011-03-15 EP EP11708256.0A patent/EP2686164B1/en not_active Not-in-force
- 2011-03-15 BR BR112013023526A patent/BR112013023526A2/en not_active IP Right Cessation
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WO1999044814A1 (en) * | 1998-03-02 | 1999-09-10 | Fabio Perini S.P.A. | Method and device for producing an embossed web material and product made in this way |
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EP3207174A4 (en) * | 2014-10-17 | 2018-05-16 | Sage Automotive Interiors Inc. | Dimensional enhancement of artificial leather polyurethane composite material |
Also Published As
Publication number | Publication date |
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EP2686164A1 (en) | 2014-01-22 |
BR112013023526A2 (en) | 2016-12-06 |
EP2686164B1 (en) | 2016-04-27 |
US20130344294A1 (en) | 2013-12-26 |
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