U.S. patent application number 13/455678 was filed with the patent office on 2012-08-23 for embossing roll assembly with mixed inclination embosses.
This patent application is currently assigned to Georgia-Pacific Consumer Products LP. Invention is credited to John H. DWIGGINS, T. Philips ORIARAN, Brian J. SCHUH, Galyn A. SCHULZ.
Application Number | 20120213965 13/455678 |
Document ID | / |
Family ID | 37573999 |
Filed Date | 2012-08-23 |
United States Patent
Application |
20120213965 |
Kind Code |
A1 |
SCHUH; Brian J. ; et
al. |
August 23, 2012 |
EMBOSSING ROLL ASSEMBLY WITH MIXED INCLINATION EMBOSSES
Abstract
An emboss pattern, tissue product and method of manufacturing
tissue product having improved bulk and softness with minimal roll
ridging. The pattern combines a plurality of aligned signature
bosses with a grouping of signature bosses offset from the machine
direction in a clockwise manner and another grouping of signature
bosses being offset in a counter-clockwise manner.
Inventors: |
SCHUH; Brian J.; (Appleton,
WI) ; DWIGGINS; John H.; (Neenah, WI) ;
ORIARAN; T. Philips; (Appleton, WI) ; SCHULZ; Galyn
A.; (Greenville, WI) |
Assignee: |
Georgia-Pacific Consumer Products
LP
|
Family ID: |
37573999 |
Appl. No.: |
13/455678 |
Filed: |
April 25, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13081047 |
Apr 6, 2011 |
8187427 |
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13455678 |
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12878334 |
Sep 9, 2010 |
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13081047 |
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12381874 |
Mar 17, 2009 |
7799161 |
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12878334 |
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11471225 |
Jun 20, 2006 |
7527851 |
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12381874 |
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60692797 |
Jun 21, 2005 |
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Current U.S.
Class: |
428/141 |
Current CPC
Class: |
B31F 1/07 20130101; Y10T
428/24777 20150115; B31F 2201/0738 20130101; Y10T 156/1023
20150115; B31F 2201/0733 20130101; Y10T 442/69 20150401; D21H
25/005 20130101; Y10T 428/24736 20150115; Y10T 428/24355 20150115;
Y10T 428/24603 20150115; Y10T 428/24992 20150115; Y10T 428/24612
20150115; D21H 27/02 20130101; Y10T 428/24479 20150115; D21H 27/002
20130101; Y10T 442/60 20150401 |
Class at
Publication: |
428/141 |
International
Class: |
B32B 3/12 20060101
B32B003/12; B32B 9/06 20060101 B32B009/06 |
Claims
1-21. (canceled)
22. An embossed paper product comprising: macro bosses forming an
interconnected pattern of tapered elliptical cells separated from
one another by embossed linear segments wherein the macro bosses
are off-set from the machine direction of the paper product.
23. The paper product of claim 22, wherein the cells are offset in
the clockwise direction from about 5.degree. to about
45.degree..
24. The paper product of claim 22, wherein the cells are offset in
the counter-clockwise direction from about 5.degree. to
45.degree..
25. The paper product of claim 22, wherein the cells of the macro
bosses contain a signature boss.
26. The paper product of claim 22, wherein the cells of the macro
bosses contain micro bosses.
27. The paper product of claim 22, wherein the macro bosses form a
pattern of nested cells.
28. The paper product of claim 27, wherein the nested cells are
separated by a pattern of bosses.
29. The paper product of claim 28, wherein the bosses separating
the nested cells are micro bosses.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 12/878,334, filed Sep. 9, 2010, which is a continuation of U.S.
application Ser. No. 12/381,874, filed Mar. 17, 2009, now U.S. Pat.
No. 7,799,161 ,which is a division of U.S. application Ser. No.
11/471,225, filed Jun. 20, 2006, now U.S. Pat. No. 7,527,851, which
claims the benefit of U.S. Provisional Application No. 60/692,797,
filed Jun. 21, 2005. The priorities of the foregoing applications
are hereby claimed and the entirety of their disclosures
incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention generally relates to paper products and more
particularly to embossed tissue products exhibiting a high
perceived softness.
BACKGROUND OF THE INVENTION
[0003] Tissue products manufactured using wet press technology can
be embossed subsequent to creping to improve bulk, appearance and
perceived softness. It is known in the art to emboss sheets
comprising multiple plies of tissue to increase the surface area of
the sheets thereby enhancing their bulk and moisture holding
capacity. Tissue products are usually marketed in rolls, containing
a specified number of sheets per roll. Tissue embossed in
conventional patterns of spot debossments, when packaged in roll
form, exhibit a tendency to be non-uniform in appearance often due
to uneven buildup of the bosses as the sheet is wound onto the
roll, resulting in a ridging effect detracting from the appearance
of the rolls.
SUMMARY OF THE INVENTION
[0004] A tissue product exhibiting improved tactile and visual
characteristics is disclosed. The tissue product is defined by a
plurality of signature boss groupings, each grouping including a
plurality of similarly aligned signature bosses. Major axes of one
of the groupings of signature bosses diverge in the clockwise
direction from the machine direction of said web, and major axes of
another of grouping of signature bosses diverge in the
counter-clockwise direction from the machine direction of said
web.
[0005] One advantage of the present invention is to provide an
embossed tissue which avoids buildup and ridging problems while
heightening the consumer's perception of softness. The pattern
which is formed in the tissue of the present invention may bc
formed by &bossing or embossing. When an emboss pattern is
formed, the reverse side of the sheet retains a deboss pattern. The
projections which are formed are referred to as bosses. When a
deboss pattern is formed, the reverse side of the sheet retains an
emboss pattern and the projections are still referred to as bosses.
Thus, the methodologies may be interchanged while producing the
same product. When the web or sheets are formed into a roll, the
tissue is aligned so that the bosses are internal to the roll and
the debossed side of the tissue is exposed.
[0006] The product according to the present invention may include
signature bosses, macro bosses and micro bosses. Signature bosses
may be made up of any embossing design. They are most often a
design which may be related by consumer perception to the
particular manufacturer of the tissue. Macro bosses and micro
bosses may assume a variety of different configurations, for
example stitch-like bosses and rounded dot-like bosses.
[0007] In one embodiment of the present invention, the boss pattern
combines relatively shallow micro bosses with deeper defined macro
bosses and signature bosses. Signature bosses may be formed of
groupings of closed linear bosses. For example, a signature boss
may be formed as groupings of closed linear bosses defining
peripheral plateaus around a central region. Groupings of signature
bosses are preferably linearly aligned. A pattern of mixed
inclinations is selected so that some of the signature boss
groupings are aligned in the machine direction, some are aligned
with a clockwise offset relative to machine direction, and some of
the signature boss groupings are aligned with a counterclockwise
offset relative to machine direction. One effect of this mixed
inclination arrangement is that the rolls possess very good roll
structure and do not exhibit the ridging effect found with prior
art embossed tissue patterns.
[0008] Signature bosses, macro bosses and micro bosses serve to
greatly enhance the bulk of the tissue while also enhancing the
distortion of the surface thereof. The signature bosses may be
groupings of continuous linear embosses and debossed to
significantly greater depth than the micro bosses. The signature
bosses and macro bosses may be embossed or debossed to an equal
height and have similarly defined boundaries. Groupings of
signature bosses may exhibit the same overall pattern but may be
scaled in size, e.g., the paper product may include two differently
scaled signature bosses. The macro bosses can define continuous or
stitchlike patterns embossed or debossed to greater depth titan
micro bosses. In addition, the signature bosses further enhance the
puffy or filled appearance of the sheet both by creating the
illusion of shading as well as by creating actual shading due to
displacement of the sheet apparently caused by puckering of
surrounding regions due to the heavy embossing or debossing given
to the signature.
[0009] The foregoing has outlined rather broadly the features and
technical advantages of the present invention in order that the
detailed description of the invention that follows may be better
understood. Additional features and advantages of the invention
will be described hereinafter which form the subject of the claims
of the invention. It should be appreciated by those skilled in the
art that the conception and specific embodiment disclosed may be
readily utilized as a basis for modifying or designing other
structures for carrying out the same purposes of the present
invention. It should also be realized by those skilled in the art
that such equivalent constructions do not depart from the spirit
and scope of the invention as set forth in the appended claims. The
novel features which are believed to be characteristic of the
invention, both as to its organization and method of operation,
together with further objects and advantages will be better
understood from the following description when considered in
connection with the accompanying figures. It is to be expressly
understood, however, that each of the figures is provided for the
purpose of illustration and description only and is not intended as
a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will be more fully understood and
further advantages will become apparent when reference is made to
the following detailed description of the invention and the
accompanying drawings wherein like numerals represent like
elements, and in which:
[0011] FIGS. 1 and 2 are devotional views of an emboss pattern for
a tissue product according to the present invention.
[0012] FIG. 3 is an elevational view of a grouping of linear
elements defining a signature emboss grouping of the most preferred
embodiment of the present invention.
[0013] FIG. 4 is a sectional view along line 4-4 in FIG. 3.
[0014] FIG. 5 is an elevational view of a portion of the emboss
pattern of FIGS. 1 and 2.
[0015] FIG. 6 is a sectional view along line 6-6 in FIG. 5.
[0016] FIG. 7 is an elevational view of a portion of the emboss
pattern of FIGS. 1 and 2.
[0017] FIG. 8 is a sectional view along line 8-8 of FIG. 7.
[0018] FIG. 9 is a sectional view along line 9-9 of FIG. 7.
[0019] FIGS. 10 and 11 are devotional views of another embodiment
of an emboss pattern for a tissue product according to the present
invention.
[0020] FIG. 12 is an devotional view of a grouping of linear
elements defining a signature emboss grouping of the embossed
pattern of FIG. 11.
[0021] FIG. 13 is a sectional view along line 13-13 in FIG. 12.
[0022] FIG. 14 is an elevational view of a portion of a grouping of
linear elements defining a signature emboss grouping of the
embossed pattern of FIG. 11.
[0023] FIG. 15 is a sectional view along line 15-15 in FIG. 14.
[0024] FIG. 16 is an elevational view of a grouping of background
micro-emboss elements of the embossed pattern of FIG. 11.
[0025] FIG. 17 is a sectional view along line 17-17 of FIG. 16.
[0026] FIG. 18 is a sectional view along line 18-18 of FIG. 17.
[0027] FIGS. 19-22 are low magnification photomicrographs of tissue
of the present invention made using the emboss pattern of FIGS.
1-9.
[0028] FIG. 23 is a photomicrographs illustrating the detail of the
differences in appearance of the three groups of emboss elements in
the tissue made according to the most preferred embodiment of the
present invention.
[0029] FIG. 24 is a photograph comparing a roll produced according
to present invention with mixed inclination signature emboss
elements and an otherwise equivalent comparison roll without mixed
inclination signature emboss elements.
[0030] FIG. 25 is a bar graph illustrating friction deviations of
tissue products according to present invention as compared to prior
art tissue products.
[0031] FIG. 26 includes results from a Home Use Test of tissue
products.
[0032] FIG. 27 includes data from a comparative experiment of
tissue products.
[0033] FIG. 28 is a schematic process flow diagram for a method of
making an embossed, rolled tissue product in accordance with the
present invention.
DETAILED DESCRIPTION
[0034] According to one embodiment of the present invention,
enhanced perceived softness, controlled sidedness, good roll
structure and good ply bonding are provided by a tissue substrate
having embossed therein a pattern which is comprised of distinct
elements, the first, an array of signature bosses, the second, an
array of macro bosses and the third, a pattern of micro bosses. The
macro bosses preferably comprise discontinuous elements that are
embossed or debossed in the tissue substrate in a pattern of a
meandering linear array. In the illustrated embodiments of the
invention, cells defined by the macro bosses are generally in the
shape of a tapered ellipse. In alternative embodiments of the
invention, the cells defined by macro bosses may be differently
configured.
[0035] The macro bosses further define generally linear sections
aligned in a predetermined direction, which may be offset from the
machine direction. The effect is a pattern having discontinuous
lines and curves defining a plurality of generally interconnected
cells. In one embodiment of the present invention, each cell
contains only a signature boss (FIGS. 1-9), while in another
embodiment the cells contain both a signature boss and a plurality
of miero bosses in a fill pattern (FIGS. 10-18). In the present
application, when describing the bosses "in front of" and "behind"
refer to the depth of the boss pattern. A boss which is embossed to
less depth is in front of a boss which is embossed to a greater
depth.
[0036] Substrates for use in the present invention include toilet
tissue. The paper substrates for forming the tissue are readily
recognizable to the skilled artisan. In one example, the paper
substrate may have a basis weight of from about 8.5 to about 15.5
pounds per 3000 square foot ream of tissue.
[0037] One embodiment of a boss pattern according to the invention
is disclosed in FIGS. 1-9, wherein macro bosses define a plurality
of nested cells each containing a signature boss. The macro boss
pattern is defined by an array of dot-like bosses extending across
the tissue field. In another embodiment of the invention as
disclosed in FIGS. 10-18, macro bosses define a plurality of cells
containing micro bosses in a fill pattern surrounding the signature
bosses. Micro bosses may define a till pattern between the nested
cells. In one embodiment of the present invention, the macro bosses
are generally dot-shaped, and the micro bosses are generally
elliptical in shape. The macro bosses can define a pattern of cells
of varying shapes. Cell shapes which can be used in the present
invention include a generally elliptical shaped cell. Other cell
shapes are readily recognizable to the skilled artisan. In a
preferred embodiment, the cells are nested and are generally
elliptical in form with tapered ends.
[0038] FIGS. 1-9 illustrate an emboss pattern for a tissue product
according to the present invention. FIGS. 1 and 2 are elevational
views of the overall pattern of the embossed pattern and disclose
small and large signature bosses 16, 18, macro bosses 20, and micro
bosses 22. The repeat pattern length is 4.4980 inches. In preferred
embodiments of the invention, the repeat pattern length is between
about 3.5 inches to about 5.5 inches.
[0039] Referring to FIG. 2, macro bosses 20 are arranged in a
plurality of closed cells 24 and broken linear segments 26. Linear
segments 26 associated with adjacent cells 24 are generally
parallel to each other and extend across the tissue paper in a
predetermined inclined direction relative to the machine direction.
Closed cells 24 are generally defined as tapered ellipses. Closed
cells 24 are arranged in nested form. In the boss pattern of FIGS.
1-9, micro bosses 22 define a fill pattern external to the closed
cells 24 containing large signature bosses 18. Groupings of
signature bosses 16, 18 are aligned in different orientations
(inclinations) relative to the machine direction. As indicated by
Line #1, small signature bosses 16 are aligned with respective
major axes being parallel to the machine direction. As indicated by
Line #2, some of the large signature bosses 18 are offset in a
clockwise direction from the machine direction. As indicated by
Line #3, other large signature bosses 18 are offset in a
counterclockwise direction relative to machine direction. FIG. 2
also illustrates that the major axes of some of the signature
bosses 18 within closed cells 24 are generally aligned in the
direction defined by broken linear segments 26, i.e., those
signature bosses 18 associated with Line #3. Other signature bosses
8 within closed cells 24 are offset relative to the direction
defined by linear segments 26, e.g., the signature bosses 18
associated with Line #2. The angular offset of bosses 18 relative
to the machine direction is preferably between about 15 degrees to
about 35 degrees.
[0040] In illustrated embodiments of the present invention,
signature bosses 16, 18 define tulip-shaped elements. FIG. 3 is an
elevational view of a grouping of linear elements defining a
signature boss grouping of the most preferred embodiment of the
present invention. Signature bosses 16 have a major axis, A.sub.1,
a minor axis, A.sub.2, and a length along the major axis being
greater than a length along the minor axis. In preferred
embodiments of the present invention, the major axis length is more
than 1.5 times greater than the minor axis length.
[0041] FIG. 4 is a sectional view along line 4-4 in FIG. 3 and
includes a cross sectional view of signature boss 18 and macro boss
20. Signature boss 18 and macro boss 20 each include a plateau 40
and downwardly extending sidewalls 42. The transition between
plateau 40 and sidewalls 42 may have a radius of curvature.
Signature boss 18 has a plateau width of 0.0200 inch, a plateau
height of 0.0600 inch, downwardly extending side walls 42 defined
by acute angles of 20 degrees, and a radius of eurvature between
plateau 40 and sidewalls 42 of 0.005 inch. Macro boss 20 has a
plateau width of 0.0530 inch, a plateau height of 0.0600 inch,
downwardly extending side walls 42 defined by acute angles of 20
degrees, and a radius of curvature between plateau 40 and sidewalls
42 of 0.010 inch.
[0042] FIG. 5 is a top view of a portion of a grouping of linear
elements defining a signature emboss grouping 16 according to an
embodiment of the present invention.
[0043] FIG. 6 is a view taken along line 6-6 in FIG. 5 and includes
a cross sectional view of micro boss 22 and small signature boss
16. Micro boss 22 has a plateau width of 0.0400 inch, a plateau
height of 0.0400 inch and downwardly extending side walls 42
defined by acute angles of 16 degrees. Signature boss 16 has a
plateau width of 0.0200 inch, a plateau height of 0.0600 inch,
downwardly extending side walls 42 defined by acute angles of 20
degrees, and a radius of curvature between plateau 40 and sidewalls
42 of 0.005 inch.
[0044] FIG. 7 is an elevational view of a grouping of background
micro boss elements 22. FIG. 8 is a sectional view along line 8-8
of FIG. 7. Micro boss elements 22 have a plateau width of 0.0400
inch, a plateau height of 0.0400 inch, downwardly extending side
walls 42 defined by acute angles of 16 degrees, and a radius of
curvature between plateau 40 and sidewalls 42 of 0.0050 inch. The
boss elements 22 are spaced 0.1124 inch in the direction defined by
section line 9-9.
[0045] FIG. 9 is a sectional view along line 9-9 of FIG. 7. Micro
boss elements 22 have a plateau width of 0.0200 inch, a plateau
height of 0.0400 inch, downwardly extending side walls 42 defined
by acute angles of 16 degrees, and a radius of curvature between
plateau 40 and sidewalls 42 of 0.0050 inch. The boss elements 22
are spaced 0.0619 inch in the direction defined by section line
10-10.
[0046] FIGS. 10-18 illustrate another emboss pattern for a tissue
product according to the invention. FIGS. 10 and 11 are elevational
view of the overall emboss pattern and disclose large and small
signature bosses 16, 18, macro bosses 20, and micro bosses 22.
[0047] Signature bosses 16, 18 define tulip-shaped elements.
Signature bosses 16, 18 have a major axis and a minor axis and a
length along the major axis being greater than a length along the
minor axis. In preferred embodiments of the present invention, the
major axis length is more than 1.5 times greater than the minor
axis length.
[0048] Macro bosses 20 define a plurality of closed cells 24 and
broken linear segments 26. Linear segments 26 associated with
adjacent cells 24 are generally parallel to each other and extend
across the tissue paper in a predetermined direction offset from
the machine direction. Closed cells 24 are generally defined as
tapered ellipses. In the embodiments of FIGS. 10-18, micro bosses
22 define a fill pattern external to the closed cells 24 containing
large signature bosses 18 and also internal to the closed cells
24.
[0049] Referring to FIG. 11, macro bosses 20 define a plurality of
closed cells 24 and broken linear segments 26. Linear segments 26
associated with adjacent cells 24 are generally parallel to each
other and extend across the tissue paper in a predetermined
inclined direction relative to the machine direction. Closed cells
24 are generally defined as tapered ellipses. In the boss pattern
embodiments of FIGS. 10-18, micro bosses 22 define a fill pattern
external to the closed cells 24 containing large signature bosses
18 and also internal within the closed cells 24. Groupings of
signature bosses 16, 18 are aligned in different orientations
(inclinations) relative to the machine direction. As indicated by
Line #1, small signature bosses 16 are aligned with respective
major axes being parallel to the machine direction. As indicated by
Line #2, some of the large signature bosses 18 are offset in a
clockwise direction from the machine direction. As indicated by
Line #3, other large signature bosses 18 are offset in a
counterclockwise direction relative to machine direction. FIG. 10,
also illustrates that the major axes of some of the signature
bosses 18 within closed cells 24 are generally aligned in the
direction defined by broken linear segments 26, i.e., those
signature bosses 18 associated with Line #3. Other signature bosses
8 within closed cells 24 are offset relative to the direction
defined by linear segments 26, e.g., the signature bosses 18
associated with Line #2. The angular offset of bosses 18 relative
to the machine direction is preferably between about 15-35
degrees.
[0050] FIG. 13 is a view taken along line 13-13 in FIG. 12 and
includes a cross sectional view of signature boss 18 and macro boss
20. Signature boss 18 and macro boss 20 each include a plateau 40
and downwardly extending sidewalk 42. The transition between
plateau 40 and sidewalls 42 may have a radius of curvature.
Signature boss 18 has a plateau width of 0.0200 inch, a plateau
height of 0.0600 inch, downwardly extending side walls 42 defined
by acute angles of 20 degrees, and a radius of curvature between
plateau 40 and sidewalts 42 of 0.005 inch. Macro boss 20 has a
plateau width of 0.0530 inch, a plateau height of 0.0600 inch,
downwardly extending side walls 42 defined by acute angles of 20
degrees, and a radius of curvature between plateau 40 and sidewalk
42 of 0.010 inch.
[0051] FIG. 14 is a top view of a portion of a grouping of linear
elements defining a signature emboss grouping 16.
[0052] FIG. 15 is a sectional view along line 15-15 in FIG. 14 and
includes a cross sectional view of micro boss 22 and usuall
signature boss 16. Micro boss 22 has a plateau width of 0.0400
inch, a plateau height of 0.0400 inch and downwardly extending side
walk 42 defined by acute angles of 16 degrees. Signature boss 18
has a plateau width of 0.0200 inch, a plateau height of 0.0600
inch, downwardly extending side walls 42 defined by acute angles of
20 degrees, and a radius of curvature between plateau 40 and
sidewalls 42 of 0.005 inch.
[0053] FIG. 16 is an elevational view of a grouping of background
micro boss elements 22 of a highly preferred embodiment of the
present invention. FIG. 17 is a sectional view along line 17-17 of
FIG. 16. Micro boss elements 22 have a plateau width of 0.0400
inch, a plateau height of 0.0400 inch, downwardly extending side
walls 42 defined by acute angles of 16 degrees, and a radius of
curvature between plateau 40 and sidewalk 42 of 0.0050 inch. The
boss elements 22 are spaced 0.1124 inch in the direction defined by
section line 17-17.
[0054] FIG. 18 is a sectional view along line 18-18 of FIG. 17.
Micro boss elements 22 have a plateau width of 0.0200 inch, a
plateau height of 0.0400 inch, downwardly extending side walls 42
defined by acute angles of 16 degrees, and a radius of curvature
between plateau 40 and sidewalis 42 of 0.0050 inch. The boss
elements 22 are spaced 0.0619 inch in the direction defined by
section line 18-18.
[0055] FIGS. 19-22 are low magnification photomicrographs of a
tissue product made using the emboss pattern of FIGS. 1-9.
[0056] FIG. 23 is a photomicrograph illustrating the differences in
appearance of the three groups of emboss elements in the tissue
made using the emboss pattern of FIGS. 1-9.
[0057] FIG. 24 is a photograph comparing a roll 10 produced
according to present invention with mixed inclination signature
emboss elements and an otherwise equivalent comparison roll 12
without mixed inclination signature emboss elements. Ridging of the
comparison roll 12 is indicated by reference numeral 14. In
comparison, roll 110 is more uniform in shape and is defined by
significantly less ridging.
[0058] FIG. 25 is a bar graph illustrating friction deviations
between the bottom and top surface of tissue products according to
present invention as compared to prior art tissue products. The
Club 6 products utilized the boss patterns of FIGS. 1-9 and the
Club 4 product utilized the boss patterns of FIGS. 10-18. As
compared to the prior art products (Club 1, Club 2, N40C), the Club
6 and Club 4 products exhibited significantly lower frictional
differences. A tissue product with a lower frictional delta is
preferred as such products provide higher perceived softness.
[0059] Consumer perception testing was carried out to rate the
quality of the product using the emboss patterns of the present
invention. In one example, market testing was conducted in which
the embossed tissues of the present invention as described in the
specification (FIGS. 1-18), was compared to prior art tissue. Three
sets of tissue rolls were prepared from substantially identical
base sheets using the patterns of FIGS. 1-9, FIGS. 10-18 and U.S.
Pat. No. 5,597,639, respectively. When tested in a Home Use Test
("HUT"), the results shown in FIG. 26 were obtained. The HUT
included a total of 1,777 test participants. The winning test
products were to have a higher overall average rating (OAR) than
the control product in order to replace the existing control
product bath tissue product. The "Current product 425 ct." refers
to sheets using the pattern of U.S. Pat. No. 5,597,639. The "425
ct. Club 6" product refers to sheets using the pattern of FIGS.
1-9, and the "425 et. Club 5" product refers to sheets using the
pattern of FIGS. 10-18. The overall average rating (OAR) of the 425
et. Club 6 pattern was the highest. Both the Club 4 and Club 6
products yield significant improvements in absorbency, softness,
attractiveness and roll life as compared to the control
product.
[0060] In another test, four sets of tissue rolls were prepared
from substantially identical base sheets using the patterns of
FIGS. 1-9 and FIGS. 10-18. When evaluated by a sensory panel, the
results of FIG. 27 were obtained.
[0061] In yet another test, two sets of tissue rolls were prepared,
one incorporating the emboss pattern of FIGS. 1-9, the other
incorporating a prior art emboss pattern. It was revealed that the
tissue rolls corresponding to FIGS. 1-9 exhibited minimal and fully
acceptable ridging while the tissue rolls corresponding to prior
art emboss patterns exhibited excessive ridging as illustrated in
FIG. 24. FIG. 24 is a photograph comparing a roll 10 produced
according to present invention with mixed inclination signature
emboss elements and an otherwise equivalent comparison roll 12
without mixed inclination signature emboss elements. Ridging of the
comparison roll 12 is indicated by reference numeral 14. In
comparison, roll 10 is more uniform in shape and is defined by
significantly less ridging.
[0062] Aspects of a method for manufacturing a tissue product of
the present invention are shown in greater detail the process flow
diagram of FIG. 28. A tissue web 100 as would be produced by a
tissue manufacturing machine is unwound from a parent roll 102 in a
conventional manner. The unwound tissue web 100 is transported to a
calendering unit 104 comprising a pair of calendering rolls 106 and
108. Upon exiting calendering unit 104, the tissue web 100 is
transported to an embossing unit 112. Embossing unit 112 comprises
a pattern roll 120 and a backing roll 122 that together define an
embossing nip 124. Embossing nip 124 may comprise a "soft-nip"
wherein the rolls have different surface hardnesses and at least
one of the rolls has a resilient surface. A resilient backing roll
122 suitable for the present invention can be a rubber covered
embossing roll, although the actual material may comprise natural
rubber, synthetic rubber, composites, or other compressible
surfaces. Suitable resilient backing rolls 122 may have a surface
hardness from about 70 to 190 Pusey & Jones, and particularly
from about 120 to 160 Pusey & Jones. For example, pattern roll
120 may comprise a smooth steel roll and backing roll 122 may be
formed of a composite polymer such as that available from Valley
Roller, Inc., under the tradename "Cool Nip Plus." The embossing
nip 124 pressure is suitably from about 100 to about 325 pounds per
lineal inch, and more particularly from about 150 to about 275
pounds per lineal inch, such that the embossing pattern is imparted
to the tissue web 100. The static coefficient of friction for
backing roll 122 is from about 1.5 to 3.0, and particularly from
about 2.0 to 2.5. The calendered and embossed tissue web 100 is
subsequently wound onto tissue roll cores to form logs at a
rewinding unit. The logs are cut into appropriate widths and the
resulting individual tissue rolls are packaged (not shown).
[0063] Although the present invention and its advantages have been
described in detail, it should be understood that various changes,
substitutions and alterations can be made herein without departing
from the spirit and scope of the invention as defined by the
appended claims. Moreover, the scope of the present application is
not intended to be limited to the particular embodiments of the
process, machine, manufacture, composition of matter, means,
methods and steps described in the specification. As one of
ordinary skill in the art will readily appreciate from the
disclosure of the present invention, processes, machines,
manufacture, compositions of matter, means, methods, or steps,
presently existing or later to be developed that perform
substantially the same function or achieve substantially the same
result as the corresponding embodiments described herein may be
utilized according to the present invention. Accordingly, the
appended claims are intended to include within their scope such
processes, machines, manufacture, compositions of matter, means,
methods, or steps.
* * * * *