CA2414668A1 - An apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength - Google Patents

An apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength Download PDF

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Publication number
CA2414668A1
CA2414668A1 CA002414668A CA2414668A CA2414668A1 CA 2414668 A1 CA2414668 A1 CA 2414668A1 CA 002414668 A CA002414668 A CA 002414668A CA 2414668 A CA2414668 A CA 2414668A CA 2414668 A1 CA2414668 A1 CA 2414668A1
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Canada
Prior art keywords
embossing
elements
cross
web
perforate
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.)
Granted
Application number
CA002414668A
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French (fr)
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CA2414668C (en
Inventor
Paul J. Ruthven
Dale T. Gracyalny
Galyn A. Schulz
John R. Demille
Otto Mogged Iii
Alan J. Kraszewski
Robert J. Williams
Harlie C. Zahn
Robert R. Daus
Mark D. Hansen
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GPCP IP Holdings LLC
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Individual
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Publication date
Priority claimed from US10/036,770 external-priority patent/US6733626B2/en
Application filed by Individual filed Critical Individual
Priority to CA2749070A priority Critical patent/CA2749070C/en
Priority to CA2749105A priority patent/CA2749105C/en
Priority to CA2749303A priority patent/CA2749303C/en
Publication of CA2414668A1 publication Critical patent/CA2414668A1/en
Application granted granted Critical
Publication of CA2414668C publication Critical patent/CA2414668C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
    • A61F13/15731—Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
    • 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
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0741—Roller cooperating with a non-even counter roller
    • B31F2201/0743—Roller cooperating with a non-even counter roller having a matching profile
    • 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
    • B31F2201/0753—Roller supporting, positioning, driving means
    • 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
    • B31F2201/0779—Control
    • 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
    • B31F2201/0797—Perforating

Abstract

An embossing system is provided for embossing a web having a first embossing roll having embossing elements and a second embossing roll having embossing elements, wherein at feast a portion of the embossing elements of the first and second embossing rolls are substantially oriented in the cross- machine direction. The embossing roll may be crowned, may have alignment means, and may be provided with precision gearing.

Claims (183)

1. ~An embossing system for embossing and perforating at least a portion of a web comprising:
a first embossing roll having embossing elements; and at least a second embossing roll having embossing elements, wherein the embossing elements of the first and second embossing rolls define perforate nips for embossing and perforating the web; and wherein at least a portion of the perforate nips are substantially oriented in the cross-machine direction.
2. ~The embossing system of claim 1 wherein substantially all of the perforate nips are substantially oriented in the cross-machine direction.
3. ~The embossing system of claim 1 wherein all of the perforate nips are substantially oriented in the cross-machine direction.
4. ~The embossing system of claim 1 wherein at least a portion of the embossing elements are male elements that are substantially oval shaped.
5. ~The embossing system of claim 1 wherein at least a portion of the embossing elements are male elements that are substantially hexagonal shaped.
6. ~The embossing system of claim 1 wherein at least a portion of the embossing elements are male elements that are substantially rectangular shaped.
7. ~The embossing system of claim 1 wherein the cross-machine embossing elements are at an angle of from at least about 60° to 120° from the machine direction.
8. ~The embossing system of claim 1 wherein the cross-machine embossing elements are at an angle of from about 85-95° from the machine direction.
9. ~The embossing system of claim 1 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 15 mils.
10. ~The embossing system of claim 9 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 30 mils.
11. ~The embossing system of claim 10 wherein at least a portion of the cross-machine embossing elements are male elements having a height of about 30 to 65 mils.
12. ~The embossing system of claim 9 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 45 mils.
13. ~The embossing system of claim 9 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 60 mils.
14. ~The embossing system of claim 1 wherein the cross-machine embossing elements are in full-step alignment.
15. The embossing system of claim 1 wherein the cross-machine embossing elements are in half-step alignment.
16. The embossing system of claim 1 wherein the cross-machine embossing elements are in quarter-step alignment.
17. The embossing system of claim 1 having a cross-machine element engagement of from about at least 15 mils.
18. The embossing system of claim 1 having a cross-machine element engagement of from about at least 16 to 32 mils.
19. The embossing system of claim 1 wherein the cross-machine embossing elements have angled sidewalls, wherein the sidewalls have an angle of less than about 20°.
20. The embossing system of claim 19 wherein the sidewall angle of the cross-machine embossing elements is less than about 17°.
21. The embossing system of claim 19 wherein the sidewall angle of the cross-machine embossing elements is less than about 14°.
22. The embossing system of claim 19 wherein the sidewall angle of the cross-machine embossing elements is less than about 11°.
23. The embossing system of claim 19 wherein the sidewall angle of the cross-machine embossing elements is from about 7° to 11°.
24. The embossing system of claim 1 wherein at least a portion of the elements have a height of about 30 mils and have an engagement of about 15 mils.
25. The embossing system of claim 1 wherein at least a portion of the elements have a height of about 30 mils and have an engagement of about 24 mils.
26. An embossing system for embossing at least a portion of a web comprising:
a first embossing roll; and at least a second embossing roll, wherein each of the first and second embossing rolls has at least one juxtaposable embossing element substantially oriented in the cross-machine direction, thereby defining a cross-machine direction perforate nip between the cross-machine direction elements for embossing and perforating the web, and wherein at least a substantial portion of the cross-machine direction elements have at least the ends beveled.
27. The embossing system of claim 26 wherein at least a portion of the embossing elements are male elements that are substantially oval shaped.
28. The embossing system of claim 26 wherein at least a portion of the embossing elements are male elements that are substantially hexagonal shaped.
29.The embossing system of claim 26 wherein at least a portion of the embossing elements are male elements that are substantially rectangular shaped.
30. The embossing system of claim 26 wherein the cross-machine embossing elements are at an angle of from at least about 60° to 120° from the machine direction.
31. The embossing system of claim 30 wherein the cross-machine embossing elements are at an angle of about 85° to 95° from the machine direction.
32. The embossing system of claim 26 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 15 mils.
33. The embossing system of claim 32 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 30 mils.
34. The embossing system of claim 32 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least from about 30 to 65 mils.
35. The embossing system of claim 32 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 45 mils.
36. The embossing system of claim 32 wherein at least a portion of the cross-machine embossing elements are male elements having a height of at least about 60 mils.
37. The embossing system of claim 26 wherein the cross-machine embossing elements are in full-step alignment.
38. The embossing system of claim 26 wherein the cross-machine embossing elements are in half-step alignment.
39. The embossing system of claim 26 wherein the cross-machine embossing elements are in quarter-step alignment.
40. The embossing system of claim 26 having a cross-machine element engagement of greater than at least about 15 mils.
41. The embossing system of claim 26 having a cross-machine element engagement of between about 16 to 32 mils.
42. The embossing system of claim 26 wherein the cross-machine embossing elements have angled sidewalls, wherein the sidewalls have an angle of less than about 20°.
43. The embossing system of claim 26 wherein the sidewall angle of the cross-machine direction elements is less than about 17°
44. The embossing system of claim 26 wherein the sidewall angle of the cross-machine direction elements is less than about 14°.

44. The embossing system of claim 26 wherein the sidewall angle of the cross-machine direction elements is less than about 11 °.
45. The embossing system of claim 26 wherein the sidewall angle of the cross-machine embossing elements is from about 7° to 11°.
46. The embossing system of claim 26 wherein at least a portion of the elements have a height of about 30 mils and have an engagement of about 15 mils.
47. The embossing system of claim 26 wherein at least a portion of the elements have a height of about 30 mils and have an engagement of about 24 mils.
48. An embossing system for embossing and perforating at least a portion of a web comprising:
a first embossing roll; and at least a second embossing roll, wherein each of the first and second embossing rolls has at least one juxtaposable embossing element defining a cross-machine direction perforate nip between the cross-machine direction elements for embossing and perforating the web, and wherein at least a substantial portion of the cross-machine direction elements have sidewall angles of less than about 20°.
49. The embossing system of claim 48 wherein the cross-machine direction elements have sidewall angles of less than about 17°.
50. The embossing system of claim 48 wherein the cross-machine direction elements have sidewall angles of less than about 14°.
51. The embossing system of claim 48 wherein the cross-machine direction elements have sidewall angles of from about 7° to 11°.
52. The embossing system of claim 48 wherein the embossing elements are substantially oval shaped.
53. The embossing system of claim 48 wherein the embossing elements are substantially hexagonal shaped.
54. The embossing system of claim 48 wherein the embossing elements are substantially rectangular shaped.
55. The embossing system of claim 48 wherein the cross-machine embossing elements are at an angle of from at least about 60° to 120° from the machine direction.
56. The embossing system of claim 48 wherein the cross-machine embossing elements are at an angle of about 85° to 95° from the machine direction.
57. The embossing system of claim 48 wherein the height of the cross-machine embossing elements is from at least about 15 mils.
58. The embossing system of claim 48 wherein the height of the cross-machine embossing elements is from at least about 30 mils.
59. The embossing system of claim 48 wherein the height of the cross-machine embossing elements is from about 30 to 65 mils.
60. The embossing system of claim 48 wherein the height of the cross-machine embossing elements is at least from about 45 mils.
61. The embossing system of claim 48 wherein the height of the cross-machine embossing elements is at least from about 60 mils.
62. The embossing system of claim 48 wherein the cross-machine embossing elements are in full-step alignment.
63. The embossing system of claim 48 wherein the cross-machine embossing elements are in half-step alignment.
64. The embossing system of claim 48 wherein the cross-machine embossing elements are in quarter-step alignment.
65. The embossing system of claim 48 having a cross-machine element engagement of from greater than about 15 mils.
66. The embossing system of claim 48 having a cross-machine element engagement of at least about 16 to 32 mils.
67. The embossing system of claim 48 wherein at least a portion of the elements have a height of at least about 30 mils and have an engagement of at least about 15 mils.
68. The embossing system of claim 48 wherein at least a portion of the elements have a height of at least about 30 mils and have an engagement of at least about 24 mils.
69. A method for embossing and perforating at least a portion of a web comprising:
providing a first embossing roll having embossing elements; and providing at least a second embossing roll having embossing elements, wherein at least a predominate number of the embossing elements are substantially oriented in the cross-machine direction and wherein the first and second embossing rolls define a perforate nip for embossing and perforating the web; and passing the web between the first and second rolls wherein the first and second embossing rolls are configured and the engagement and alignment therebetween are controlled to result in an element clearance that will achieve a non-picking clearance while achieving at least a 15% reduction in the machine direction tensile strength of the web.
70. The method of claim 69 wherein the embossing elements are substantially oval shaped.
71. The method of claim 69 wherein the embossing elements are substantially hexagonal shaped.
72. The method of claim 69 wherein the embossing elements are substantially rectangular shaped.
73. The method of claim 69 wherein the cross-machine embossing elements are at an angle of from about at least 60° to 120° from the machine direction.
74. The method of claim 70 wherein the cross-machine embossing elements are at an angle off about 85° to 95° from the machine direction.
75. The method of claim 70 wherein the height of the cross-machine embossing elements is from at least about 15 mils.
76. The method of claim 70 wherein the height of the cross-machine embossing elements is from at least about 30 mils.
77. The method of claim 70 wherein the height of the cross-machine embossing elements is from about 30 to 65 mils.
78. The method of claim 70 wherein the height of the cross-machine embossing elements is at least from about 45 mils.
79. The method of claim 70 wherein the height of the cross-machine embossing elements is at least from about 60 mils.
80. The method of claim 70 wherein the cross-machine embossing elements are in full-step alignment.
81. The method of claim 70 wherein the cross-machine embossing elements are in half-step alignment.
82. The method of claim 70 wherein the cross-machine embossing elements are in quarter-step alignment.
83. The method of claim 70 having a cross-machine element engagement of from at least about 15 mils.
84. The method of claim 70 having a cross-machine element engagement of from about 16 to 32 mils.
85. The method of claim 70 wherein the cross-machine embossing elements have angled sidewalls, wherein the sidewalls have an angle of less than about 20°.
86. The method of claim 70 wherein the sidewall angle of the cross-machine elements is less than about 17°.
87. The method of claim 70 wherein the sidewall angle of the cross-machine elements is less than about 14°.
88. The method of claim 70 wherein the sidewall angle of the cross-machine elements is less than about 11°.
89. The method of claim 70 wherein the sidewall angle of the cross-machine embossing elements is from about 7° to 11°.
90. A method for reducing the tensile ratio of a web by embossing and perforating the web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having embossing elements and at least a second embossing roll having embossing elements, wherein the first and second embossing rolls define a plurality of perforate nips for embossing and perforating the web; and wherein at least a predominant number of the perforate nips are substantially oriented in the cross-machine direction.
91. The method of claim 90 wherein the tensile ratio of the web is reduced by at least 10% of the difference between the base web tensile ratio and 1.
92. The method of claim 90 wherein the tensile ratio of the web is reduced by at least 20% of the difference between the base web tensile ratio and 1.
93. The method of claim 90 wherein the tensile ratio of the web is reduced by at least 30% of the difference between the base web tensile ratio and 1.
94. The method of claim 90 wherein substantially all of the perforate nips are substantially oriented in the cross-machine direction.
95. The method of claim 90 wherein all of the perforate nips are substantially oriented in the cross-machine direction.
96. A method for reducing the tensile ratio of a web by embossing and perforating the web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having at least one embossing element oriented substantially in the cross-machine direction and at least a second embossing roll having at least one juxtaposable embossing element oriented substantially in the cross-machine direction, thereby defining a cross-machine direction perforate nip between the cross-machine direction elements for embossing and perforating the web; and wherein at least a substantial portion of the cross-machine direction elements have at least the ends beveled.
97. A method for reducing the tensile ratio of a web by embossing and perforating the web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having at least one embossing element oriented substantially in the cross-machine direction and at least a second embossing roll having at least one embossing element oriented substantially in the cross-machine direction, thereby defining a cross-machine direction perforate nip between the cross-machine direction elements for embossing and perforating the web; and wherein at least a portion of the cross-machine direction elements have cross-machine direction sidewall angles of less than about 20°.
98. The method of claim 97 wherein at least a portion of the cross-machine direction elements have cross-machine direction sidewall angles of less than about 11°.
99. The method of claim 97 wherein at least a portion of the cross-machine direction elements have cross-machine direction sidewall angles of from about 7° to 11°.
100. A method for reducing the tensile ratio of a web by embossing and perforating the web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having embossing elements and at least a second embossing roll having embossing elements, wherein the first and second embossing rolls define a perforate nip extending in the cross machine direction for embossing and perforating the web; and wherein the first and second embossing rolls are configured to, and the engagement and alignment are controlled to, result in an element clearance that will achieve a non-picking clearance.
101. The method of claim 69, 90, 96, 97, or 100 wherein the web is a creped web.
102. The method of claim 101 wherein the web is creped with an undulatory creping blade.
103. The method of claim 69, 90, 96, 97, or 100 wherein the web is calendered.
104. A perforate embossed web having a plurality of cross-machine direction oriented perforations wherein the embossed web has a tensile ratio of less than about 1.2.
105. A perforate embossed web having a transluminance ratio of at least 1.005.
106. The perforate embossed web of claim 105 having a transluminance ratio of at least 1.01.
107. A wet-laid cellulosic perforate embossed web having perforate embossments extending predominately in the cross-machine direction.
108. The wet-laid cellulosic perforate embossed web having perforate embossments extending predominately in the cross-machine direction of claim 107 wherein the perforate embossments extend in the cross-machine direction for at least about 20 mils.
109. The wet-laid cellulosic perforate embossed web having perforate embossments extending predominately in the cross-machine direction of claim 107 wherein the angle between the perforate embossments extending in the cross-machine direction and the machine direction of the web is between 60° and 120°.
110. The wet-laid cellulosic perforate embossed web having perforate embossments extending predominately in the cross-machine direction of claim 107 wherein said perforate embossments extend substantially through the thickness of the web.
111. The wet-laid cellulosic perforate embossed web according to claim 105 having a transluminance ratio of at least 1.02.
112. A method of embossing and perforating the web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having embossing elements and at least a second embossing roll having embossing elements, wherein the first and second embossing rolls define a plurality of perforate nips for embossing and perforating the web; and wherein the tensile ratio of the web is reduced by at least about 5% of the difference between the tensile ratio of the base sheet and 1Ø
113. The embossing system of claim 1, 26, or 48 wherein at least a first portion of the cross-machine embossing elements are male elements having a height of at least about 15 mils and wherein at least a second portion of the cross-machine embossing elements are male elements having a height of at least about 15 mils and wherein the height of the second portion elements is greater than that of the first portion elements.
114. An embossing system for perforate embossing at least a portion of a web comprising:
a first embossing roll having embossing elements; and at least a second embossing roll having embossing elements, wherein the embossing elements of the first and second embossing rolls define perforate nips for embossing and perforating the web, wherein at least a portion of at least the first or second embossing roll is crowned, and wherein at least a portion of the perforate nips are substantially oriented in the cross-machine direction.
115. The embossing system according to claim 114 wherein at least a portion of each of the first and second embossing rolls is crowned.
116. The embossing system according to claim 114 wherein the crown of the embossing roll is substantially parabolic in shape.
117. The embossing system according to claim 114 wherein the crown is at least approximately 1 mil.
118. The embossing system according to claim 114 wherein the crown is at least approximately 2 mils.
119. The embossing system according to claim 114 wherein the crown is at least approximately 3 mils.
120. The embossing system according to claim 114 wherein the crown is at least approximately 5 mils.
121. A perforate embossing roll having embossing elements wherein at least a majority of the embossing elements are substantially oriented in the cross-machine direction and wherein the embossing roll is crowned.
122. The perforate embossing roll according to claim 121 wherein the crown of the embossing roll is substantially parabolic in shape.
123. The perforate embossing roll according to claim 121 wherein substantially all of the embossing elements are substantially oriented in the cross-machine direction.
124. The perforate embossing roll according to claim 121 wherein the crown is at least approximately 1 mil.
125. The perforate embossing roll according to claim 121 wherein the crown is at least approximately 2 mils.
126. The perforate embossing roll according to claim 121 wherein the crown is at least approximately 3 mils.
127. The perforate embossing roll according to claim 121 wherein the crown is at least approximately 5 mils.
128. An embossing system for perforate embossing at least a portion of a web comprising:
a first embossing roll having embossing elements, the first embossing roll being in communication with a first gear; and at least a second embossing roll having embossing elements, the second embossing roll being in communication with a second gear, wherein the embossing elements of the first and second embossing rolls define perforate nips for embossing and perforating the web; and wherein at least a portion of the perforate nips are substantially oriented in the cross-machine direction, and wherein the first gear and the second gear have a precision rating of greater than Q-6.
129. The embossing system according to claim 128 further including a precision hub.
130. The embossing system of claim 128 wherein the first gear and the second gear have a precision rating of at least about Q-8.
131. The embossing system of claim 128 wherein the first gear and the second gear have a precision rating of at least about Q-10.
132. The embossing system of claim 128 wherein the first gear and the second gear are pre-heat treated gears.
133. The embossing system of claim 128 wherein the first gear and the second gear are hobbed gears.
134. The embossing system of claim 128 wherein the first gear and the second gear are ground gears.
135. The embossing system according to claim 128 wherein the first gear and the second gear are shaved gears.
136. An embossing system for perforate embossing at least a portion of a web comprising:
a first embossing roll having embossing elements, the first embossing roll having a first alignment means; and at least a second embossing roll having embossing elements, the second embossing roll having a second alignment means, wherein the embossing elements of the first and second embossing rolls define perforate nips for embossing and perforating the web and wherein at least a portion of the perforate nips are substantially oriented in the cross-machine direction.
137. The embossing system of claim 136 wherein at least the first or second alignment means includes a collar having a keyway.
138. The embossing system of claim 136 wherein the first alignment means includes an adjustable collar and the second alignment means includes a fixed collar.
139. The embossing system of claim 136 wherein at least the first or second alignment means includes scribe marks.
140. The embossing system of claim 136 wherein the first and second alignment means include matched keyways.
141. A perforate embossing roll having embossing elements wherein at least a majority of the embossing elements are substantially oriented in the cross-machine direction and wherein the embossing roll has an alignment means.
142. The perforate embossing roll according to claim 141 wherein substantially all of the embossing elements are substantially oriented in the cross-machine direction.
143. The perforate embossing roll according to claim 141 wherein the alignment means includes an adjustable collar.
144. The perforate embossing roll according to claim 141 wherein the alignment means includes a scribe mark.
145. The perforate embossing roll according to claim 141 wherein the alignment means includes a fixed collar.
146. The perforate embossing roll according to claim 141 wherein the alignment means includes a matched keyway.
147. A method of engaging at least two perforate embossing rolls comprising:
providing a first embossing roll having at least a portion of the embossing elements substantially oriented in the cross-machine direction, the embossing roll having a first collar, and the first collar having a first keyway;
providing at least a second embossing roll having at least a portion of the embossing elements substantially oriented in the cross-machine direction, the embossing roll having a second collar, and the second collar having a second keyway;
bringing the first and second embossing rolls into close proximity;
aligning the first and second keyways; and bringing the first and second embossing rolls into engagement.
148. The method according to claim 147 wherein at least the first or second collar is an adjustable collar ring.
149. A method for perforate embossing at least a portion of a web comprising:
providing a first embossing roll having embossing elements; and providing at least a second embossing roll having embossing elements, wherein at least a portion of at least the first or second embossing roll is crowned, and wherein at least a predominate number of the embossing elements of the first and second embossing rolls are substantially oriented in the cross-machine direction, and wherein the first and second embossing rolls define a perforate nip for perforate embossing the web; and passing the web between the first and second rolls wherein the first and second embossing rolls are configured and the engagement and alignment therebetween are controlled to result in an element clearance that will achieve a non-picking clearance while achieving at least a 15% reduction in the machine direction tensile strength of the web.
150. The method according to claim 149 wherein at least a portion of each of the first and second embossing rolls is crowned.
151. The method according to claim 149 wherein the crown is substantially parabolic in shape.
152. The method according to claim 149 wherein the crown is at least approximately 1 mil.
153. The method according to claim 149 wherein the crown is at least approximately 2 mils.
154. The method according to claim 149 wherein the crown is at least approximately 3 mils.
155. The method according to claim 149 wherein the crown is at least approximately 5 mils.
156. A method for embossing and perforating at least a portion of a web comprising:
providing a first embossing roll having embossing elements, the first embossing roll being in communication with a first gear; and providing at least a second embossing roll having embossing elements, the second embossing roll being in communication with a second gear, wherein at least a predominate number of the embossing elements are substantially oriented in the cross-machine direction and wherein the first and second embossing rolls define a perforate nip for embossing and perforating the web, and wherein the first gear and the second gear have a precision rating of greater than Q-6; and passing the web between the first and second rolls wherein the first and second embossing rolls are configured and the engagement and alignment therebetween are controlled to result in an element clearance that will achieve a non-picking clearance while achieving at least a 15% reduction in the machine direction tensile strength of the web.
157. The method according to claim 156 wherein the first gear and the second gear have a precision rating of at least about Q-8.
158. The method according to claim 156 wherein the first gear and the second gear have a precision rating of at least about Q-10.
159. The method according to claim 156 wherein the first gear and the second gear are pre-heat treated.
160. The method according to claim 156 wherein the first gear and the second gear are hobbed gears.
161. The method according to claim 156 wherein the first gear and the second gear are ground gears.
162. The method according to claim 156 wherein the first and second gears are shaved gears.
163. The method according to claim 156 further including a precision hub.
164. A method for perforate embossing a web without increasing the MD/CD tensile ratio of the web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having embossing elements and at least a second embossing roll having embossing elements, wherein at least a portion of at least the first or second embossing rolls are crowned, and wherein the first and second embossing rolls define a plurality of perforate nips for embossing and perforating the web; and wherein at least a predominant number of the perforate nips are substantially oriented in the cross-machine direction.
165. The method according to claim 164 wherein at least a portion of each of the first and second embossing rolls is crowned.
166. The method according to claim 164 wherein the crown is substantially parabolic.
167. A method for perforate embossing a web without increasing the MD/CD tensile ratio of the web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having embossing elements and wherein the first embossing roll is in communication with a first gear, and at least a second embossing roll having embossing elements, wherein the second embossing roll is in communication with a second gear, the first and second gears having a precision rating of at least Q-6, and wherein the first and second embossing rolls define a plurality of perforate nips for embossing and perforating the web; and wherein at least a predominant number of the perforate nips are substantially oriented in the cross-machine direction.
168. The method according to claim 167 further including a precision hub.
169. A method of perforate embossing a web comprising:

passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having embossing elements and at least a second embossing roll having embossing elements, wherein the first and second embossing rolls define a plurality of perforate nips for embossing and perforating the web, and wherein at least a portion of at least the first embossing roll or the second embossing roll is crowned; and wherein the MD/CD tensile ratio of the web is not increased.
170. The method according to claim 169 wherein at least a portion of each of the first and second embossing rolls is crowned.
171. A method of perforate embossing a web comprising:
passing a web through an embossing system, wherein the embossing system comprises a first embossing roll having embossing elements, wherein the first embossing roll is in communication with a first gear, and at least a second embossing roll having embossing elements, wherein the second embossing roll is in communication with a second gear, the first and second gears having a precision rating of greater than Q-6, and wherein the first and second embossing rolls define a plurality of perforate nips for embossing and perforating the web;
and wherein the MD/CD tensile ratio of the web is not increased.
172. A perforate embossing roll having embossing elements wherein at least a portion of the embossing elements are substantially oriented in the cross-machine direction, wherein the embossing roll is in communication with a gear, and wherein the gear has a precision rating of greater than Q-6.
173. The perforate embossing roll according to claim 172 wherein the gear has a precision rating of at least approximately Q-8.
174. The perforate embossing roll according to claim 172 wherein the gear has a precision rating of at least approximately Q-10.
175. The perforate embossing roll according to claim 172 wherein the gear is a pre-heat treated gear.
176. The perforate embossing roll according to claim 172 wherein the gear is a hobbed gear.
177. The perforate embossing roll according to claim 172 wherein the gear is a ground gear.
178. The perforate embossing roll according to claim 172 wherein the gear is a shaved gear.
179. An embossing system for perforate embossing at least a portion of a web comprising:
a first embossing roll having embossing elements; and at least a second embossing roll having embossing elements, wherein the embossing elements of the first and second embossing rolls define perforate nips for embossing and perforating the web, wherein the first and second embossing rolls have an alignment means, and wherein at least a portion of the perforate nips are substantially oriented in the cross-machine direction.
180. The embossing system of claim 179 wherein the alignment means includes a collar having a keyway.
181. A method of engaging at least two embossing rolls comprising:
providing a first embossing roll having perforate embossing elements substantially oriented in the cross machine direction;
providing at least a second embossing roll having perforate embossing elements substantially oriented in the cross machine direction, the first and second embossing rolls having an alignment means;
bringing the first and second embossing rolls into close proximity;
aligning the alignment means; and bringing the first and second embossing rolls into engagement.
182. The method according to claim 181 wherein the alignment means includes a collar having a keyway.
183. A method of perforate embossing a web wherein at least a majority of the perforations are substantially oriented in the cross-machine direction and wherein the caliper profile, Delta c, of the web is less than 2.
CA2414668A 2001-12-21 2002-12-17 An apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength Expired - Lifetime CA2414668C (en)

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CA2749070A CA2749070C (en) 2001-12-21 2002-12-17 An apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength
CA2749105A CA2749105C (en) 2001-12-21 2002-12-17 An apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength
CA2749303A CA2749303C (en) 2001-12-21 2002-12-17 Method of embossing and perforating a web having a transluminance ratio

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US10/036,770 US6733626B2 (en) 2001-12-21 2001-12-21 Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength
US10/036,770 2001-12-21
US10/236,993 2002-09-05
US10/236,993 US6887349B2 (en) 2001-12-21 2002-09-05 Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength

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US20050092195A1 (en) 2005-05-05
US7326322B2 (en) 2008-02-05

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