High softness embossed tissue with nesting prevention embossed pattern

This invention relates to the discovery that the perceived softness of embossed tissue can be increased greatly while avoiding prior art nesting problems if a particular pattern is embossed into the tissue. This pattern combines relatively shallow stitchlike debossments with deeper more sharply defined signature debossments. The stitchlike debossments are rounded and arranged in wavy flowing intersecting lines. The signature debossments are arranged in regions framed by the intersecting wavy flowing lines.

BACKGROUND 
1. Field of the Invention 
The invention relates to an embossed tissue exhibiting a high perceived 
softness. The invention further relates to a roll of embossed tissue. The 
embossed tissue of the invention results in superior overall appearance of 
the product as well as a consumer perception of improved softness. The 
embossed tissue of the present invention also results in a more uniformly 
rolled tissue. 
2. Background of the Invention 
Tissue produced using conventional wet press technology must usually 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 creped tissue to increase the surface area of the sheets thereby 
enhancing their bulk and water holding capacity. Toilet tissue is usually 
marketed in rolls, containing a specified number of sheets per roll. 
Tissue embossed in conventional patterns of spot embossments, when 
packaged in roll form, exhibit a tendency to be non-uniform in appearance 
often due to uneven buildup of the debosses as the sheet is wound onto the 
roll, resulting in a ridging effect detracting from the appearance of the 
rolls. 
Prior art embossing patterns have been set forth which emboss products in a 
manner selected to avoid nesting of the bosses in rolled, folded or 
stacked sheets of paper product by various means. For one example of such 
a pattern, see U.S. Pat. No. 4,659,608. 
The present invention provides an embossed tissue which avoids buildup and 
ridging problems while heightening the consumers perception of softness. 
In the present invention, the embossing pattern combines relatively 
shallow stitchlike debossments with deeper more sharply defined signature 
debossments. The overall arrangement of the pattern is selected so that, 
even though the sheet is embossed heavily in the signature debossments, 
the signature debossments fully overlap at a maximum of two locations in 
the roll, the outermost of these being at least about an eighth of an inch 
inward frown the exterior surface of the roll. Moreover, the overall 
average emboss density is substantially uniform for each machine direction 
strip in the roll. The combined effect of this arrangement is that the 
rolls possess very good roll structure and do not exhibit the ridging 
effect found with prior art emboss patterns. 
This invention further relates to the discovery that the perceived softness 
of embossed tissue can be increased greatly if a particular pattern is 
embossed into the tissue. This pattern combines relatively shallow 
stitchlike debossments with deeper more sharply defined debossments. The 
shallow, stitchlike debosses are positioned to give a "puffy" quilted 
appearance creating the both actual shading and the illusion of shading as 
would be seen in a quilt having chambers filled with fiber or down. This 
appearance results from the use of stitchlike rounded debossments arranged 
in wavy flowing intersecting lines both to simulate the appearance of 
stitches of a quilt as well as to distort the actual shape of the quilt so 
that the shape and appearance cooperate to reinforce the "quiltlike" 
appearance. The waviness of the lines simulates the appearance of 
stitching displaced from straight lines by the filling in the quilt while 
creating the appearance of shading resulting from a three dimensional 
shape. In addition, the wavy flowing lines of debossments actually distort 
the sheet producing a shape resembling the surface of a filled quilt. 
Signature debossments in regions framed by the intersecting wavy flowing 
lines serve to greatly enhance the bulk of the tissue while also enhancing 
the distortion of the surface. The signature debossments are elongate and 
continuous rather than stitchlike, and are embossed to significantly 
greater depth and have more sharply defined boundaries than the 
debossments defining the wavy flowing lines. In addition, the signature 
debossments 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 caused by the heavy emboss given to the signature. 
SUMMARY OF THE INVENTION 
The objects and advantages of the invention wile be set forth in part in 
the description which follows and in part will be obvious from the 
description, or may be learned by practice of the invention. The objects 
and advantages of the invention may be realized and attained by means of 
the instrumentalities and combinations particularly pointed out in the 
appended claims. 
To achieve the foregoing objects and in according with the purpose of the 
invention, as embodied and broadly described herein, there is disclosed: 
A sheet of tissue having a plurality of debossments formed therein defining 
a lattice pattern having a plurality of polygonal cells, a fraction, less 
than all, of said polygonal cells being filled with a signature 
debossment, said lattice pattern being defined by a sinuous gracile array 
of stitchlike debossments undulating about the generators of said lattice 
pattern, said stitchlike debossments being encompassed by upwardly flaring 
regions; said signature being comprised of a plurality of elongated 
debossments having a depth of deboss exceeding the depth of deboss of said 
stitchlike debossments, said elongate debossments being encompassed by 
upwardly flaring regions encompassing said stitchlike debossments being 
more steeply inclined than the upwardly flaring regions encompassing said 
stitchlike debossments. 
There is further disclosed, a sheet of tissue having a plurality of 
debossments formed therein defining a lattice pattern having a plurality 
of polygonal cells, a fraction, more than one-third but less than 
two-thirds, of said polygonal cells being filled with a signature 
debossment, said lattice pattern being defined by a sinuous gracile array 
of stitchlike debossments undulating about the generators of said lattice 
pattern, said stitchlike debossments being encompassed by rotund arcuate 
regions having cross-sectional radii of curvature exceeding at least about 
0.010 inch; said signature being comprised of a plurality of elongated 
debossments having a depth of deboss exceeding the depth of deboss of said 
stitchlike debossments by at least 0.005 inch, said elongate debossments 
being encompassed by arcuate regions having cross-sectional radii of 
curvature of the arcuate regions encompassing said stitchlike debossments. 
There is further disclosed: 
A roll of embossed tissue having a plurality of debossments formed therein, 
said debossments comprising: 
two series of intersecting sinuous lines of stitchlike debossments, one 
series of lines being disposed at a first acute angle clockwise of the 
machine direction of the roll, the other series of lines being disposed at 
a second acute angle counterclockwise of the machine direction of the roll 
whereby a repeating pattern comprising an oblique lattice of substantially 
uniform staggered wavy diamonds is defined; 
a plurality of signature debosses centrally located within alternating rows 
of said diamond, the disposition of said debossments being configured such 
that substantial nesting of said signature debossments on said rolls 
occurs at a maximum of two locations on said roll, the outermost of said 
locations being spaced at least 0.10 inch below the exterior surface of 
said roll and, the innermost, at least 0.5 inch inward from said outermost 
substantial nesting location. 
There is still further disclosed: 
A roll of embossed tissue having a plurality of debossments formed therein, 
said debossments comprising: 
two equally spaced series of intersecting sinuous lines of stitchlike 
debossments, one series of lines being disposed at a first acute angle 
clockwise of the machine direction of the roll, the other series of lines 
being disposed at a second acute angle counterclockwise of the machine 
direction of the roll whereby an oblique lattice of substantially uniform 
staggered wavy diamonds is defined; 
a plurality of signature debosses centrally located within alternating rows 
of said diamond, the disposition of said debossments being configured such 
that, adjacent to the surface of said roll, signature debossments on 
closely adjacent overlapping repeats are displaced from each other by at 
least 0.5 inch in the machine direction. 
Additional objects and advantages of the invention will be set forth in 
part in the description which follows, and in part will be obvious from 
the description, or may be learned by practice of the invention. The 
objects and advantages of the invention will be realized and attained by 
means of the elements and combination particularly pointed out in the 
appended claims. 
The accompanying drawings, which are incorporated in and constitute a part 
of the specification, illustrate various aspects of the invention and, 
together with the description, serve to explain the principles of the 
invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
According to the present invention, a greatly enhanced perceived softness 
is provided by a tissue substrate having embossed therein a pattern which 
is comprised of two distinct elements, the first, an array of stitchlike 
debossments and the second, a signature debossment. The stitchlike 
debossment comprises rounded discontinuous structures that are embossed in 
the tissue substrate in a pattern having a horn-like upwardly flare in a 
pattern of rounded lines. The effect is a pattern, e.g. diamond shapes, 
having discontinuous curved, "wavy" lines. Superimposed over this pattern 
is a signature debossment which appears inside the overlapping pattern of 
the stitchlike debossment. Thus, the signature debossment, e.g., tulips, 
are located within the stitchlike debossment pattern, e.g., inside the 
diamonds. 
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 preferred embodiment of this invention, debossments are formed 
defining a lattice pattern having a plurality of polygonal cells, a 
fraction, less than all, preferably more than 1/3 but less than 2/3, of 
the polygonal cells being filled with a signature debossment, said lattice 
pattern being defined by a sinuous gracile array of stitchlike debossments 
undulating about the generators of the lattice pattern, the stitchlike 
debossments being encompassed by rotund, horn-like upwardly flaring, 
arcuate regions having cross-sectional radius of curvature exceeding at 
least about 0.015 inch, more preferably at least about 0.025 inch and most 
preferably at least about 0.050 inch; the signature being comprised of a 
plurality of elongate debossments having a depth of deboss exceeding the 
depth of deboss of the stitchlike debossments by at least 0.003 inch, more 
preferably at least 0.005 inch and most preferably 0.007 inch, the 
elongate debossments being encompassed by horn-like upwardly flaring, 
arcuate regions having cross-sectional radii of curvature of not more than 
50% of the average radius of curvature of the arcuate regions encompassing 
the stitchlike debossments, more preferably not more that 25% and most 
preferably not more than 15%. The cells created by the pattern of 
stitchlike debossment frame the signature debossment. 
In accordance with one embodiment of the present invention, the stitchlike 
debossment should have an area of less than 10%, preferably 8%, more 
preferably 6%. The signature debossment should have an area of less than 
5%, preferably less than 4%, more preferably less than 3%, the total 
percent area of debossments being less than about 20%, preferably less 
than about 15%, more preferably less than about 10%. 
According to one embodiment of the present invention, adjacent each side of 
each cell containing signature debossment are cells which do not contain 
signature debossment. Further, the width of the tissue sheet is 
approximately 3 cells wide. The length of the side walls of the cells is 
about 1.5 inches, more preferably 1.25 inches and most preferably 1.125 
inches. The center of the farthest stitchlike debossment is at least 1 
diameter but no more than 3 diameters from the line generating the 
polygonal cell. The array of stitchlike debossments coincides with 
generators at least 2 times between apices. 
In one embodiment of the present invention, the stitchlike debossments are 
dashes. The dashes have an aspect ratio of less than 5, more preferably 
between 3 and 5. 
The lattice can define cells of varying shape. Shapes which can be used in 
the present invention include diamond shaped cells, hexagonal cells or 
octagonal cells. Other cell shapes are readily recognizable to the skilled 
artisan. In a most preferred embodiment, the cells are diamond shaped. 
In another preferred embodiment, a roll of embossed tissue having a smooth 
exterior surface is provided by arranging the two classes of debossments 
formed in the tissue as follows: the first class of debossments comprises 
two series of intersecting sinuous lines of stitchlike debossments, one 
series of lines being disposed at a first acute angle clockwise of the 
machine direction of the roll between 15.degree. and 30.degree. the other 
series of lines being disposed at a second acute angle counterclockwise of 
the machine direction of the roll between 45.degree. and 65.degree. 
thereby forming as a repeating pattern an oblique lattice of substantially 
uniform staggered wavy diamonds. Alternate cross direction cells in these 
rolls are filled with signature debosses centrally located. The 
disposition of the debossments is such that substantial nesting of the 
signature embosses on the rolls occurs at a maximum of two locations on 
the roll, the outermost of the locations being spaced at least 1/32 inch 
below the exterior surface of the roll, more preferably at least 1/16 inch 
below and most preferably at least 0.100 inch below, and, the innermost, 
at least 0.5 inch inward from the outermost substantial nesting location, 
more preferably at least 0.75 inch and most preferably at least 0.825 
inch. 
In still another preferred embodiment, between the outermost nesting 
location and the innermost nesting location, in at least 40% of the volume 
of said roll the signature debossments do not overlap each other, more 
preferably at least 45% and most preferably at least 50%. 
In a further embodiment is provided, a roll of embossed tissue having a 
plurality of debossments formed therein, the debossments having two 
equally spaced series of intersecting sinuous lines of stitchlike 
debossments, one series of lines being disposed at a first acute angle 
clockwise of the machine direction of the roll, the other series of lines 
being disposed at a second acute angle counterclockwise of the machine 
direction of the roll whereby an oblique lattice of substantially uniform 
staggered wavy diamonds is defined. The tissue further having a plurality 
of signature debosses centrally located with in alternating rows of the 
diamond, the disposition of the debossments being configured such that, 
adjacent to the surface of the roll, signature debossments on closely 
adjacent overlapping repeats are displaced from each other by at least 0.5 
inch, more preferably by at least 0.75 inch and most preferably 1.0 inch. 
In FIG. 1, several sheet of embossed tissue are illustrated. The pattern 
includes signature debossments in the shape of tulips which are included 
within a criss-cross pattern of wavy lines which define cells having a 
diamond shape. As can be seen from FIG. 1, the wavy lines are formed from 
stitchlike or dotlike embossing. 
FIG. 2 illustrates the actual pattern for formation of the embossing 
depicted in FIG. 1. Views "3" and "4" set forth in FIG. 2 correspond to 
FIGS. 3 and 4, respectively. In FIG. 2, the numbered circles 1-46 define 
the stitchlike debossment which forms the cells, as shown herein having a 
diamond pattern. As can be seen the debossments are carried inside, across 
and external the solid lines or generators forming the diamond shape. This 
indicates the rounded or wavy shape that the lines take. 
The dots 1-46 correspond to the rectangular coordinates as set forth in 
Table 1 below: 
TABLE 1 
______________________________________ 
RECTANGULAR 
DOT # COORDINATES 
______________________________________ 
1 -.0124,.0464 
2 -.0880,.1136 
3 -.1569,.1667 
4 -.2469,.2179 
5 -.3373,.2528 
6 -.4248,.3063 
7 -.5004,.3735 
8 -.5853,.4410 
9 -.6801,.4877 
10 -.7681,.5225 
11 -.8463,.5781 
12 -.9202,.6418 
13 -.9451,.7345 
14 -.8892,.8231 
15 -.8332,.9069 
16 -.7701,.9860 
17 -.7165,.1.0722 
18 -.6868,1.1699 
19 -.6904,1.2649 
20 -.6701,1.3554 
21 -.6093,1.4321 
22 -.5485,1.5113 
23 -.4925,1.5951 
24 -.4539,1.6917 
25 -.3800,1.6281 
26 -.3018,1.5724 
27 -.2138,1.5376 
28 -.1190,1.4910 
29 -.0341,1.4235 
30 .0415,1.3562 
31 .1291,1.3027 
32 .2195,1.2678 
33 .3094,1.2166 
34 .3783,1.1636 
35 .4539,1.0963 
36 .4788,1.0036 
37 .4402,.9070 
38 .3842,.8232 
39 .3234,.7440 
40 .2626,.6673 
41 .2423,.5768 
42 .2459,.4818 
43 .2162,.3841 
44 .1626,.2979 
45 .0995,.2187 
46 .0435,.1349 
______________________________________ 
Rectangular coordinates for points 1-9, which define the tulip pattern, are 
set forth in Table 2, below: 
TABLE 2 
______________________________________ 
RECTANGULAR 
PT # COORDINATES 
______________________________________ 
1 -.1709,.4963 
2 -.2463,.5976 
3 -.2771,.6501 
4 -.4982,.8486 
5 -.2304,.7340 
6 .0467,.7845 
7 -.1884,.8766 
8 -.3286,1.1910 
9 -.2135,1.1849 
______________________________________ 
As seen in FIG. 2, the signature debossment is a plurality of closed 
segments. Internal dimensions for the signature debossment and relative 
distances between the two types of debossments are given in FIG. 2. 
The signature debossment is separated from the stitchlike debossment by at 
least 3 dot diameter, more preferably 4, most preferably 5. The dot 
diameter is at least one and one half times the signature line width, more 
preferably at least twice the signature line width, and most preferably at 
least three times the signature line width. 
The total stitchlike debossment area in FIG. 2 is 0.0022 sq. inches and 
corresponds to 3.7% of the surface area of the pattern. 
The total signature debossment area in FIG. 2 is 0.0683 sq. inches and 
corresponds to 2.6% of the surface area of the pattern. 
The total surface area of the sketch is 5.2007 sq. inches and the total 
surface area of pattern per sketch area is 6.3%. 
The internal angles of polygonal cells are about 77.degree. and about 
103.degree.. 
FIG. 3 illustrates a cross sectional view of the stitchlike debossments 
which form the cellular pattern. The diameter of the debossment has been 
measured from the apex, in 0.005 inch increments to the depth of the 
debossment of 0.050 inches. The dot diameters are set forth in Table 3 
below. 
TABLE 3 
______________________________________ 
SECTIONED 
DPTH DOT DIAMETER 
______________________________________ 
.005 .040 
.010 .055 
.015 .065 
.020 .072 
.025 .078 
.030 .082 
.035 .087 
.040 .092 
.045 .096 
______________________________________ 
FIG. 4 illustrates a cross sectional view of the signature debossment 
pattern which is found internal the diamond pattern in FIG. 2. As can be 
seen from FIG. 4, the depth of debossment is about 0.060 inches with an 
apex diameter of 0.020 inches. 
FIG. 5 illustrates the pattern configuration relative to the machine 
direction of the roll. The measured angle of the lines relative to the 
machine direction are set forth in Table 4, below: 
TABLE 4 
______________________________________ 
LINE NO. ANGLE IN X-Y PLANE 
______________________________________ 
#1 143.6.degree. 
#2 105.0.degree. 
#3 66.0.degree. 
#4 14.5.degree. 
______________________________________ 
Line 1 and line 3 indicate not only the angle of the tulip pattern, as do 
lines 2 and 4, but also indicate the angle of the generators which define 
the sinuous criss-cross pattern. 
The angle of line 1, relative to the machine direction, is preferably 
between 45.degree. and 65.degree., more preferably 54.degree.. 
The angle of line 2, relative to the machine direction, is adjusted 
accordingly in the preferred embodiment it is 15.degree.. 
The angle of line 3, relative to the machine direction, is preferably 
between 15.degree. and 30.degree., more preferably 24.degree.. 
The angle of line 4, relative to the machine direction is adjusted 
accordingly, in the preferred embodiment, it is 75.5.degree.. 
FIG. 6 is a photograph illustrating one pattern of the present invention on 
a roll structure. 
FIG. 7 is a photograph of a tissue product embossed with one pattern 
described herein. FIG. 7 shows the wavy appearance stitchlike and 
signature debossments and the effect of this embossing on the tissue 
substrate. 
FIG. 8 is an enlargement of FIG. 1 to clarify the distinct embossing 
elements. It is clear from FIG. 8 that the signature regions and the 
stitchlike regions differ, thereby rendering a quiltlike appearance to the 
tissue. 
FIG. 9A is a photograph of a roll of the prior art embossed tissue. FIG. 9B 
is a photograph of a roll of embossed tissue according to the present 
invention. These photographs illustrate the difference between the 
structure of the rolls of the present invention and the prior art rolls of 
embossed tissue, and allow observation of the decreased ridging in the 
product of the present invention. 
FIG. 10 illustrates the location of adjacent signature debossments on 
underlying and overlying sheets of the rolled product. The relative 
positions are indicated at roll radii of 0.75, 0.887, 1.166, 1.33 and 1.79 
inches. FIG. 10 also illustrates that, when signatures on underlying and 
overlying sheets are passing those in the adjacent columns as the roll is 
filled, the signatures in adjacent columns just barely are superimposed at 
their very extremities, thus the roll builds uniformly. 
Substantial nesting of the signature pattern occurs at a radius of 0.887 
inch and 1.79 inches for a roll having a core of 1.5 inches and an outside 
diameter of 4.2 inches. Based upon core diameter and pattern diameter, 
calculation of regions of substantial overlap would be readily apparent to 
the skilled artisan. 
FIG. 11 is a photomicrograph of the cross-section of a signature 
debossment. As can be seen, the cross-section is substantially identical 
to that set forth in FIG. 4. 
FIG. 12 is a photomicrograph of the cross-section of a stitchlike 
debossment. As can be seen, the cross-section is substantially identical 
to that set forth in FIG. 3. 
FIGS. 13 and 14 illustrate the gentler slope and shallower embossing of the 
stitchlike debossment in FIG. 13 from the steeper slope and deeper 
embossing of the signature debossment of FIG. 14. This combination of two 
debossments improves the perception of softness. 
Other embodiments of the invention will be apparent to those skilled in the 
art from consideration of the specification and practice of the invention 
disclosed herein. It is intended that the specification and examples be 
considered as exemplary only, with a true scope and spirit of the 
invention being indicated by the following claims.