Patent Description:
Hygiene or wiping products primarily include all kinds of dry-creped tissue paper, wet-creped paper, TAD-paper (Through Air Drying), paper based on structured technologies such as Atmos, NTT, UCTAD) and cellulose or pulp-wadding or all kinds of non-wovens, or combinations, laminates or mixtures thereof. Typical properties of these hygiene and wiping products include the reliability to absorb tensile stress energy, their drapability, good textile-like flexibility, properties which are frequently referred to as bulk softness, a high surface softness and a high specific volume with a perceptible thickness. A liquid absorbency as high as possible and, depending on the application, a suitable wet and dry strength as well as an appealable visual appearance of the outer product's surface are desired. These properties, among others, allow these hygiene and wiping products to be used, for example, as cleaning wipes such as paper or non-woven wipes, windscreen cleaning wipes, industrial wipes, kitchen paper or the like; as sanitary products such as for example bathroom tissue, paper or non-woven handkerchiefs, household towels, towels and the like; as cosmetic wipes such as for example facials and as serviettes or napkins, just to mention some of the products that can be used. Furthermore, the hygiene and wiping products can be dry, moist, wet, printed or pretreated in any manner. In addition, the hygiene and wiping products may be folded, interleaved or individually placed, stacked or rolled, connected or not, in any suitable manner.

Due to the above description, the products can be used for personal and household use as well as commercial and industrial use. They are adapted to absorb fluids, remove dust, for wrapping or even just as supporting material, as is common for example in medical practices or in hospitals.

If tissue paper is to be made out of pulp, the process essentially comprises a forming that includes a box and a forming wire portion, and a drying portion, either through air drying or conventional drying on a yankee cylinder. The production process also usually includes the crepe process essential for tissues and, finally, typically a monitoring and winding area.

Paper can be formed by placing the fibers, in an oriented or random manner, on one or between two continuously revolving wires of a paper making machine while simultaneously removing the main quantity of water of dilution until dry-solids contents of usually between <NUM> and <NUM>% are obtained.

Drying the formed primary fibrous web occurs in one or more steps by mechanical and thermal means until a final dry-solids content of usually about <NUM> to <NUM>% has been reached. In case of tissue making, this stage is followed by the crepe process which crucially influences the properties of the finished tissue product in conventional processes.

The conventional dry crepe process involves creping on a usually <NUM> to <NUM> diameter drying cylinder, the so-called yankee cylinder, by means of a crepe doctor with the aforementioned final dry-solids content of the raw tissue paper. Wet creping can be used as well, if lower demands are made of the tissue quality. The creped, finally dry raw tissue paper, the so-called base tissue, is then available for further processing into the paper product for a tissue paper product.

Instead of the conventional tissue making process described above, the use of a modified technique is possible in which an improvement in specific volume is achieved by a special kind of drying which leads to an improvement in the bulk softness of the tissue paper. This process, which exists in a variety of subtypes, is termed the TAD (Through Air Drying) technique. It is characterized by the fact that the "primary" fibrous web that leaves the forming and sheet making stage is pre-dried to a dry-solids content of about <NUM>% before final contact drying on the yankee cylinder by blowing hot air through the fibrous web. The fibrous web is supported by an air-permeable wire or belt or TAD-fabric and during its transport is guided over the surface of an air-permeable rotating cylinder drum, the so-called TAD-cylinder. Structuring the supporting wire or belt makes it possible to produce any pattern of compressed zones broken up by deformation in the moist state, also named molding, resulting in increased mean specific volumes and consequently leading to an increase of bulk softness without decisively decreasing the strength of the fibrous web.

The processing step from the base tissue that has already been optionally wound up in several plies to the finished tissue product occurs in processing machines (converting machines) which include operations such as unwinding the base tissue, repeated smoothing of the tissue, printing embossing, to an extent combined with full area and/or local application of adhesive to produce ply adhesion of the individual plies to be combined together as well as longitudinal cut, folding, cross cut, placement and bringing together a plurality of individual tissues and their packaging as well as bringing them together to form larger surrounding packaging or bundles. Such processing steps may also include application of substances like scents, lotions, softeners or other chemical additives. The individual paper ply webs can also be pre-embossed and then combined in a roll gap according to the embossing methods known in the art. Any embossing can lead to embossed elements all having the same height or to embossing elements having different heights. Ply bonding, e.g. by mechanical or by chemical means are other well-known methods mainly used for hankies, napkins, household towels and bathroom tissues.

A well-known technique to increase the thickness of a paper product is to emboss the paper web. An embossing process is carried out in the nip between an embossing roll and an anvil roll. The embossing roll can have protrusions or depressions on its circumferential surface leading to embossed protrusions in the paper web.

Anvil rolls may be softer than the corresponding embossing roll and may consist of rubber, such as natural rubber, or plastic materials, paper or steel.

For manufacturing multi-ply tissue products, especially bathroom tissue and household tissue, three manufacturing methods for embossing and adhesively bonding of the plies have established. These are Goffra Incolla/spot embossing, DESL (Double Embossing Single Lamination)/Nested and Pin-to-Pin/Foot-to-Foot.

In the first mentioned manufacturing method, Goffra Incolla, a first web is directed through the nip between an embossing roll and an anvil roll. In this nip the web is provided with an embossing pattern. Thereafter, an application roll for adhesive applies adhesive to those parts of the first web at which there are protruding embossing elements in the embossing roll. The adhesive is transported from an adhesive bath via an adhesive transfer roll to the application roll.

A second web is transported to the first web and adhesively bonded to the first web in the nip between the so-called marrying roll and the embossing roll. The adhesive bonding takes place at those portions at which the adhesive was applied.

The second manufacturing method (DESL/Nested) is very similar to the above-described Goffra Incolla method. It comprises an additional pair of rolls consisting of a second embossing roll and a second anvil roll. The additional pair of rolls serves to emboss the second web before it is adhesively bonded to the first web using the marrying roll. Typically, the additional pair of rolls is placed close to the first pair of rolls and the marrying roll. Especially when using the so-called Nested-method such close arrangement is important. The Nested-method can be considered as a special case of the general DESL-manufacturing method. For the Nested-method the embossing elements of the first embossing roll and the embossing elements of the second embossing roll are arranged such that the embossed elements of the first embossed ply and the embossed elements of the second embossed ply fit into each other similar to a gearing system. This serves to achieve a mutual stabilization of the two plies. However, for the DESL manufacturing method such correlation between the embossed elements of the first, upper ply and the second, lower ply, does not have to apply. Nevertheless, in the literature the term DESL is often used synonymous to a Nested-method.

The third manufacturing method (Pin-to-Pin/Foot-to-Foot) is similar to the DESL method. By means of two pairs of rolls both the upper ply and the lower ply are embossed, respectively. Adhesive is applied onto the embossed protrusions of the first ply. The ply bonding however, is not achieved by means of a marrying roll as in the DESL method but is achieved directly by means of the protruding embossing elements of the second embossing roll. In order to achieve this, an exact adjustment of the width of the nip between the first embossing roll and the second embossing roll is required, which is mainly defined by the individual thickness of both webs (upper ply and lower ply). Further, the embossing rolls have to be designed such that the protruding embossing elements of both rolls face each other. This is the reason why the terminology Pin-to-Pin or Foot-to-Foot embossing is used.

All above described methods have the following common features: the first embossing roll is formed of a hard material, usually metal, especially steel, but there are also known embossing rolls made of hard rubber or hard plastics materials. The embossing rolls can be a male roll having individual protrusions. Alternatively, the embossing roll can be a female roll with individual embossing depressions. Typical depths of the engraved embossing patterns are between <NUM> and <NUM>.

The anvil roll typically has a rubber coating with a hardness between <NUM> Shore A and <NUM> Shore A. However, structurized anvil rolls, especially rolls made of paper, rubber or plastics materials or steel are also known.

The applicator roll for adhesive is usually also a rubber roll with a plain smooth circumferential surface, wherein the hardness of the rubber coating is between the hardness of the anvil roll and the hardness of the marrying roll. Commonly used values for the hardness of the rubber coating are <NUM> to <NUM> Shore A. When selecting the rubber material its compatibility with the adhesive to be applied has to be ensured.

The application system for adhesive consisting of applicator roll, adhesive transfer roll and adhesive bath can be designed as a so-called immersion roll system in which the adhesive transfer roll is immersed into the adhesive bath and transports adhesive by means of surface tension and adhesive forces out of the adhesive bath. By adjusting the gap between the adhesive transfer roll and the applicator or application roll, the amount of adhesive to be applied can be adjusted. Application rolls may be structured rolls. Recently, adhesive transfer rolls have become known having defined pit-shaped depressions in their circumferential surface. Such adhesive transfer rolls are known as Anilox-rolls. Such roll is usually made of ceramic material or it is a roll made of steel or copper and coated with chromium. Excessive adhesive is removed from the surface of the Anilox-roll by means of a blade. The amount of adhesive is determined by the volume and the number of depressions. Alternative application systems for applying adhesives are based on spraying equipment (Weko-technique).

A second possibility to influence the amount of adhesive transferred is the adjustment of the difference in circumferential speeds of the adhesive transfer roll and the applicator roll. Typically, the adhesive transfer roll rotates slower than the applicator roll. The circumferential speed of the adhesive transfer roll is usually between <NUM>% and <NUM>% of the first circumferential speed of the applicator roll. The adhesive bath can be designed as a simple trough, application systems with a blade can also be designed as chamber systems.

The embossing technologies Goffra Incolla/spot embossing and DESL/Nested, both use an additional roll, the so-called marrying roll for laminating together the plies. The marrying roll commonly has a smooth rubber surface with a hardness of about <NUM>-<NUM> Shore A, especially <NUM>-<NUM> Shore A.

A suitable material is e.g. NBR (acrylnitrile-butadien rubber). However, marrying rolls also have become known which, in addition to the rubber coating, are provided with a steel coating. Such steel coating is often provided in form of a steel band spirally wound onto the rubber coating.

In case that the single layers individually or together are pre-embossed, a so-called micro-pre-embossing device is used. Such pre-embossing device is often used in combination with the Goffra Incolla technology. Also commonly used is a printing onto the tissue product before or after the ply bonding step. Also known are variants including the application of chemical substances, especially lotions and softeners.

Another well-known embossing technique comprises a steel embossing roll and a corresponding anvil steel roll (so-called Union embossing). The surfaces of these rolls are being formed in such a manner that deformation of the paper and mechanical ply bonding without using adhesives are achieved within one single embossing step.

When using all of the above described three embossing methods it is advantageous to provide a control for the tension of the web both before and after the ply bonding because the physical properties of the web and especially the stress-strain characteristic can be changed significantly in the embossing step.

The embossing technology also comprises so-called "double height embossing" whereby the embossing protrusions have different heights.

The embossing not only serves to provide bulk to the fibrous product but also to provide an improved optical appearance to the product. The optical appearance can be improved by combining embossing and coloring steps. Another reason for embossing is to generate higher absorbency or improved perceived softness.

As is well-known in the art, it is not possible to separately optimize the characteristics of a tissue product (absorption, softness, strength, thickness, water dispersibility,. ) because some of the factors are conflicting. For example an increase of the grammage in order to increase the thickness, absorbency and strength will lead to a more rigid ply (lower softness) and a lower dispersibility. A higher rigidity is usually linked to a lower dispersibility. The perceived softness of a product which is important for the consumers has to be balanced with the strength of the product so that it becomes more difficult to poke through. Therefore, it is not possible to optimize the individual properties of a tissue material one after the other. An overall structure has to be developed which provides a good compromise between the individual characteristics with special emphasis on a high absorbency and good performance with respect to those factors which are mainly to be achieved.

It is desirable to provide a tissue product with high absorbency, strength and thickness but also high softness and water dispersibility. Not covered by the present invention, but disclosed herein are also , a method for producing such product and an apparatus for carrying out such method.

<CIT> describes a hybrid tissue product with four plies made of tissue paper base sheet. There are two inner plies between a first outer ply and a second outer ply. One of the inner plies is un-embossed and one outer ply comprises a décor embossing pattern.

<CIT> discloses tissue products with four or more plies. Two inner plies are un-embossed, and one of the outer plies is provided with a décor embossing pattern.

The disclosure of the invention relates to a tissue product with the features of claim <NUM>. Preferred embodiments follow from the other claims.

The tissue product with at least four plies made of tissue paper base sheet or non-woven comprises a first outer ply and a second outer ply and at least two inner plies between the first outer ply and the second outer ply. At least one of the outer plies comprises a décor embossing pattern and at least one of the inner plies is un-embossed. The absorbency of the tissue product is between <NUM>/g and <NUM>/g. The absorbency may be between <NUM>/g and <NUM>/g.

The shape of the individual protrusions or depressions of the décor embossing can range from circular dots to elongate linear protrusions in the shape of lines with a constant or varying width. The décor embossing pattern has a protrusion density of less than 10protrusions/cm<NUM>, preferably less than <NUM> dots/cm<NUM>. The height of the décor embossing pattern ranges from <NUM> to <NUM> and especially between <NUM> and <NUM>. The décor embossing pattern consists of a plurality of such individual décor embossing protrusions or depressions which are arranged to generate an aesthetical appearance of a simple geometrical shape or pattern or can be recognized as a "sketch" of an item like flowers, clouds, one or more animals or the like.

According to the present disclosure, any combination of dry creped plies, wet creped plies and structured plies can be used. At least one of the inner plies is un-embossed which means that this ply is not embossed by means of a contact with an embossing roll before it is fed to the final ply-bonding. Multi-ply products can also be hybrid products when it is desired to manufacture a product with a degree of two-sidedness. Especially, the tissue paper can be produced from paper-making fibers according to "Conventional Processes" (CWP) as in the manufacture of "Dry Creped Tissue" or "Wet Crepe Tissue" or "Process for Structured Tissue" such as the Through Air Drying (TAD) manufacturing method, the manufacture of un-creped through-air dried (UCTAD) tissue, or alternative manufacturing methods, e.g. the Advanced Tissue Molding System (ATMOS) of the company Voith, or Energy Efficient Technologically Advanced Drying eTAD of the company Georgia Pacific, or Structured Tissue Technology SST of the company Metso Paper. Hybrid processes like NTT (New Textured Tissue of the company Metso Paper) which are alternations of the conventional processes can be used, too.

The fibrous tissue product according to the present disclosure is especially a tissue paper product, non-woven product or a hybrid thereof, and preferably a hygiene and cleaning product. Most preferably, the fibrous tissue product according to the present disclosure is bathroom tissue.

The term non-woven according to ISO <NUM>, DIN EN <NUM> is applied to a wide range of products which, in terms of their properties are located between those of paper (DIN <NUM>, May <NUM>) and cardboard (DIN <NUM>) on the one hand, and textiles on the other hand. As regards non-wovens a large number of extremely varied production processes are used, such as the air-laid and spun-laced techniques as well as the wet-laid techniques. The non-wovens include mats, non-woven fabrics and finished products made thereof. Non-wovens may also be called textile-like composite materials, which represent flexible porous fabrics that are not produced via the classic methods of weaving warp and weft or by looping. In fact, non-wovens are produced by intertwining, cohesive or adhesive bonding of fibers, or a combination thereof. The non-woven material can be formed of natural fibers, such as cellulose or cotton fibers, but can also consist of synthetic fibers such as polyethylene (PE), polypropylene (PP), polyurethane (PU), polyester, fibers on the basis of polyethylene-terephtalate, polyvinyl alcohol, nylon or regenerated cellulose or a mix of different fibers. The fibers may, for example, be present in the form of endless fibers or pre-fabricated fibers of a finite length, as synthetic fibers, or in the form of staple fibers. The non-wovens as mentioned herein may thus consist of mixtures of synthetic and cellulose fibrous material, e.g. natural vegetable fibers (see ISO <NUM>, DIN EN <NUM>).

The term "hygiene products" and "cleaning products" as used herein comprise bathroom tissue, household towels, handkerchiefs, facial tissues, napkins, wiping and cleaning products as well table ware.

The measurement of the absorbency as well as other characteristics of the tissue product will be described in detail below. All characteristics as mentioned and claimed herein are measured as described below.

In a multi-ply product, the advantages and especially the improved strength and absorbency are more pronounced when there is an increased number of plies. However, the advantage of adding one further ply becomes less pronounced with an increasing number of plies. Therefore, it is preferred that the maximum number of plies is eight, and more preferably the maximum number of plies is six plies. A product with four plies or five plies was found to be a good compromise with high softness and absorbency and still not too high thickness of the product.

Preferably, the tissue product comprises a first outer ply and a second outer ply and at least two inner plies between the first outer ply and the second outer ply, wherein at least one ply is a micro-embossed ply.

If one of the outer plies is micro embossed, it is given a textured appearance or might create a visual appearance of a textile fabric.

A micro-embossed inner ply increases the thickness and absorption capability of the product if the density and position of the micro-embossed protrusions is selected such that they do not nest into embossed protrusions of an adjacent outer ply.

According to an embodiment, only one of the inner plies is un-embossed. Such structure serves to generate an increased bulk to the product because the remaining inner plies and the outer plies all can be embossed in a suitable way to generate a high bulk. Finally, an un-embossed inner ply could be sandwiched between embossed inner plies and prevents an undesired nesting of the inner embossed inner plies. Further, such an unembossed inner ply is also advantageous in that it reduces the so-called back-side effect which describes the effect that a user can feel the glued area on the back side of the product which reduces the perceived softness.

Preferably, at least two adjacent inner plies comprise the un-embossed inner ply and one micro-embossed inner ply.

Preferably, the plies are adhesively bonded to each other using glue which may be non-colored or colored.

For laminating together the single webs, different types of adhesive can be used. Suitable adhesives are, inter alia, glue on the basis of starch or modified starch like for example methyl cellulose or carboxylized methyl cellulose and adhesively acting polymers on the basis of synthetic resins, caoutchouc, polypropylene, polyisobutylene, polyurethane, polyacrylates, polyvinylacetat or polyvinyl alcohol. Such adhesives can also contain dyes in order to improve the optical appearance of the finished products. Frequently, water-based glues are used for laminating together paper layers.

Preferably, when laminating together a top ply and an inner ply by means of an adhesive, the adhesive is supplied towards the protruding parts of the embossing roll. This technique for applying the adhesive can be used in combination with all predominantly used manufacturing techniques. In an attempt to influence the mechanical behavior of the multi-ply tissue product, the glue is be applied selectively on specific protrusions of the embossing roll. In other words, the adhesive is not applied to all protrusions but only in selected sections of the embossing roll so that the overall ratio of the surface area in which adhesive has been applied relative to the overall surface area can be varied within a broad range.

The use of glue is another means to influence the technical properties of the combined product, especially the overall stiffness of the tissue product.

If colored glue is used, this is selected in order to give a specific optical appearance to the product.

In order to combine a plurality of plies and specially two plies together, the plies are preferably adhesively bonded together at the tips of the embossing patterns of the plies facing each other.

According to a preferred embodiment, the application of glue is restricted to an overall surface fraction of less than <NUM>%, preferably less than <NUM>% of the tissue product.

A small amount of glue generates a tissue product with a high softness.

Preferably, the tissue product either comprises a stack of individual sheets or a roll with transversely extending weakening lines to subdivide the web into individual sheets.

Preferably, each sheet has a width between <NUM> and <NUM>, preferably between <NUM> and <NUM> and most preferably around <NUM>, and a length between <NUM> and <NUM>, preferably between <NUM> and <NUM>, and most preferably around <NUM>, and each sheet has a sheet area between <NUM><NUM> and <NUM><NUM>, and preferably between <NUM><NUM> and <NUM><NUM>. The specific length of around <NUM> at a width of around <NUM> has not been used so far for bathroom tissue.

It is preferred that the ratio between length and width of each sheet of the tissue product ranges from <NUM>:<NUM> to <NUM>:<NUM> and more preferably from <NUM>:<NUM> to <NUM>:<NUM>.

In case of the preferred size of each sheet with a width of around <NUM> and a length of around <NUM>, the absorbency of each sheet is between <NUM>/sheet and <NUM>/sheet and preferably between <NUM>/sheet and <NUM>/sheet.

According to a preferred embodiment, the thickness of the tissue product is between <NUM> and <NUM> and preferably between <NUM> and <NUM>.

According to a preferred embodiment, the basis weight of the tissue product is between <NUM>/m<NUM> and <NUM>/m<NUM>, and preferably between <NUM>/m<NUM> and <NUM>/m<NUM>.

Preferably, the outer plies comprise a micro-embossing pattern with outer embossed protrusions, and the density of the inner micro-embossed protrusions of the micro-embossed inner ply is different to the density of the outer embossed protrusions of the micro-embossing pattern of the outer ply which is adjacent to the micro-embossed inner ply.

The different densities of the embossed protrusions of the inner ply and the adjacent outer ply avoid the nesting of the embossed protrusions which increases the bulk and the softness of the tissue product.

Preferably, at least one of the embossed plies comprises a double layer or plural layers.

According to a preferred embodiment, a considerable portion of the outwardly facing main surface of the first outer ply is provided with at most three distinct soft regions, such as one soft region, surrounded by a décor embossing region, respectively. Each soft region is provided with first micro-embossed protrusions and the décor embossing region comprises first embossed décor protrusions. The first micro-embossed protrusions are essentially not adhesively bonded to an inner ply adjacent to the top ply.

Since the first micro-embossed protrusions are essentially not adhesively bonded to any other ply , the softness of the tissue product is considerably increased. The softness perceived by a user becomes pronounced if the soft region is surrounded by the décor embossing region. The term "surrounded" also covers an arrangement of individual spaced décor protrusions. The overall design is such that the soft region is perceived to be surrounded by the décor region. However, in order to be perceived as a soft region surrounded by a décor embossing region of first outer ply, such soft region is preferably a single coherent region or at least subdivided in at most three sub-regions. The décor embossing serves for the adhesion of the plies and can also be used to provide an aesthetically pleasing appearance to the product.

Preferably, in each soft region the local absorbency of the tissue product exceeds the absorbency in the remaining part of the tissue product by at least <NUM>%, preferably between <NUM>% and <NUM>%, more preferably at least <NUM>%, and most preferably between <NUM>% and <NUM>%. Hence, the soft region or regions do not only impart an increased perceived softness to the product but also contribute to the increased overall absorbency of the product. Further, the liquid tends to be collected in that part of the sheet where it is used.

Preferably, a surface fraction of the remaining part of the tissue product contains more glue than at least one soft region. Thus, the remaining part of the tissue product can advantageously comprise more glue per surface area than the soft region or soft regions. This serves to achieve a proper ply bonding in the product without having to add glue in the soft region or region.

It was found to be advantageous if the first micro-embossed protrusions of the first outer ply and/or the embossed protrusions of the micro-embossing pattern of the micro-embossed inner ply and/or the protrusions of a second micro-embossing pattern of the second outer ply are arranged in a density from <NUM> to <NUM> dots/cm<NUM>. Typically, a density of about <NUM> dots/cm<NUM> is used. The micro embossing tips or engravings on the embossing roll have a height ranging between <NUM> and <NUM>.

A density above <NUM> dots/cm<NUM> and even up to <NUM> dots/cm<NUM> has not been feasible for a long time. Only with the option to manufacture embossing rolls using 3D-printing, it has become possible to generate embossing rolls with such a high density of embossing projections on its circumferential surface. Micro embossing with such a very fine pattern simulates the textured appearance of a TAD product and creates a visual appearance of a textile fabric.

The claimed technology works for any densities of the embossed protrusions but it is more efficient if the density is high. It has been found that a higher density of the embossed protrusions contributes to the perceived softness of the product. At the same time, the absorbency performance also increases with the density of the embossed protrusions, because the absorbency is linked to the density and depth of the embossed protrusions.

Preferably, a middle ply adjacent to first outer ply is provided with a décor embossing region with further embossed décor protrusions which are in register with the first embossed décor protrusions.

Preferably, the density of the embossed protrusions of the micro-embossing pattern of the inner ply is different to the density of the protrusions of the second micro-embossing pattern of the second outer ply, preferably smaller than the density of the protrusions of the second micro-embossing pattern of the second outer ply.

Such different densities avoid that these two plies are nesting.

According to a preferred embodiment the soft region or soft regions surrounded by the décor embossing region covers between <NUM>% and <NUM>%, preferably between <NUM>% and <NUM>%, and most preferably around <NUM>% of the outwardly facing main surface of the first outer ply.

The larger the soft region is in relation to the surface area of one sheet of the product, the higher is the perceived softness for the user. On the other hand, if the soft region is selected to be too high, the required ply bonding and integrity of the product can no longer be ensured.

Therefore, the claimed range between <NUM>% and <NUM>% was found to provide a good compromise between perceived softness and mechanical stability of the multi-ply product.

Preferably, the soft region has an overall oval shape. Such a shape follows the rectangular shape of individual sheets so that a relatively large surface area of each sheet can be covered by the soft region. However, the soft region can be circular or rectangular or can show any other regular, irregular, symmetrical or not symmetrical shape.

According to a preferred embodiment, the décor embossing region of the first outer ply further comprises second embossed décor protrusions with a smaller height than the height of the first embossed décor protrusions.

The provision of second embossed décor protrusions with a smaller height than the height of the first embossed décor protrusions makes it possible to further reduce the amount of glue which can only be applied to the first embossed décor protrusions with a higher height. A small amount of glue results in a higher softness of the product. Further, the aesthetic appearance can be improved by providing different types of décor protrusions.

According to a preferred embodiment, the un-embossed inner ply is adjacent to the first outer ply or second outer ply.

Preferably, at least three inner plies are provided and a first inner ply not adjacent to the first outer ply or second outer ply is provided with a micro-embossing pattern, and a second inner ply between the first inner ply and either the first outer ply or second outer ply is un-embossed.

The third ply needs not to be fully covered by the micro-embossing pattern in order to achieve the advantageous effect of an increased bulk. According to a preferred embodiment, the micro-embossing pattern of the first inner ply extends essentially all over the surface of the first inner ply.

Advantageously, less than <NUM>% of the number of micro-embossed protrusions of the outer ply are adhesively bonded to the other plies. Such a small proportion of the micro-embossed protrusions which are bonded to an adjacent inner ply further increase the perceived softness of the product because the soft region of the first outer ply can be slightly moved relative the adjacent inner ply. Such a relative movement in the main plane of the product largely contributes to soft feeling when handling the product.

According to a preferred embodiment, the embossing is in register with the dimensions of the individual sheets of the tissue product.

This has the advantage that each sheet has exactly the same embossing pattern. The soft region can be arranged centered on each individual sheet.

The device for manufacturing a tissue product as disclosed herein comprises a first engraved roll running against a first anvil roll, wherein the first engraved roll is designed to emboss the first outer ply, a glue application device adjacent to the first engraved roll, and a marrying roll cooperating with the first engraved roll. A second engraved roll runs against a second anvil roll, wherein the second engraved roll is arranged and designed to emboss the second outer ply. A third engraved roll runs against a third anvil roll, wherein the third engraved roll is arranged to emboss one of the inner plies. The device further comprises means to direct at least one un-embossed inner ply towards the first engraved roll downstream of the nip between the first engraved roll and the marrying roll.

The device needs only a relatively small number of machine components, because the individual plies are all directed towards the first engraved roll and the final ply bonding takes place between the first engraved roll and the marrying roll.

The anvil roll is preferably made of rubber like EPDM or NBR (nitrylbutadien rubber), paper or steel.

Preferably, the anvil roll has a hardness between <NUM> Shore A and <NUM> Shore A, preferably between <NUM> Shore A and <NUM> Shore A and most preferably a hardness between <NUM> Shore A and <NUM> Shore A.

Preferably, the first engraved roll has a repeating pattern of embossing protrusions with décor embossing regions surrounding regions provided with micro-embossing protrusions.

The provision of both the décor embossing pattern and the micro-embossing pattern on the first engraved roll further reduces the number of required machine components, because no additional pre-embossing station is required to provide the micro-embossing pattern on the first outer ply before providing that the core embossing pattern in an additional embossing step.

It has been found that a higher height of the embossed protrusions improves the aesthetic appearance of the product.

Preferably, the device further comprises an additional embossing roll and a cooperating anvil roll for embossing one of the inner plies.

Preferably, the device further comprises a perforating device to generate transversely extending weakening lines to subdivide the web into individual sheets.

According to a first preferred alternative, the device further comprises a stacking device to form stacks of individual sheets of the tissue product.

Preferably, the apparatus further comprises a folding unit for providing a folded tissue product.

According to a second preferred alternative, the device further comprises a winding device to form rolls of the perforated or un-perforated tissue product.

The method for manufacturing a tissue product according to the present disclosure comprises the steps:.

The method according to the present disclosure requires only a relatively small number of manufacturing steps, because the individual plies are all directed towards the first engraved roll and the final ply bonding takes place between the first engraved roll and the marrying roll.

Preferably, in the method according to the present disclosure an un-embossed ply is brought in direct contact with the embossed first outer ply or second outer ply.

Preferably, the method further comprises the step of directing a second inner ply into the nip between a fourth roll running against a fourth anvil roll.

Such process step can be used to emboss an inner ply with a micro-embossing pattern which is different to the micro-embossing pattern of an adjacent outer ply.

According to a preferred embodiment, two un-embossed inner plies and one embossed inner ply are used, wherein the embossed inner ply is sandwiched between the two un-embossed inner plies.

Preferably, when using two un-embossed inner plies, these two un-embossed inner plies are not in contact with each other. In order to achieve the desired bulk of the product, it was found to be advantageous to arrange an embossed inner ply and two un-embossed inner plies such that the embossed inner ply is arranged between the two un-embossed inner plies.

Preferably, in step (a) either two first outer plies or two second outer plies are embossed together.

Preferably, in step (a) and/or step (d) the outer ply is embossed in two separate steps which is a first pre-embossing step to provide the micro-embossing pattern followed by a second décor embossing step to provide the décor embossing.

The provision of the micro-embossing pattern and the décor embossing pattern in two separate method steps makes it possible to generate complex embossed geometries even with a superposition of the different embossing patterns. Further, such method might be beneficial when an existing process already using a pre-embossing step is modified to manufacture the product according to the present disclosure.

In the drawings, some embodiments are shown.

In the following description of exemplary, preferred embodiments, the same reference numerals will be used for the same or similar elements.

<FIG> shows an example of a multi-ply tissue product according to the present disclosure. The tissue product <NUM> has a first outer ply <NUM> which is a top ply, and a second outer ply <NUM> which is a bottom ply. In the following, reference will be made to top ply and bottom ply, respectively, although there is no definition as to which of the outer plies is supposed to be the top ply.

The top ply <NUM> and the bottom ply <NUM> are both provided with an embossing pattern including micro-embossed protrusions <NUM>. However, it is also possible to provide the top ply and/or the bottom ply as so-called structured plies, for example manufactured by means of a Through Air Drying Process.

In the example according to <FIG>, two inner plies <NUM>, <NUM> are provided. The second inner ply <NUM> adjacent to the bottom ply <NUM> is un-embossed which means that the second inner ply <NUM> is not embossed by means of a contact with an embossing roll before it is fed to the final ply-bonding.

The first inner ply <NUM> between the second inner ply <NUM> and the top ply <NUM> is micro-embossed in order to increase the bulk of the tissue product <NUM>.

The height h3 of the embossed protrusions 8a of the top ply <NUM> can be different to the height h1 of the embossed protrusions 8b of the bottom ply <NUM>. Further décor embossed protrusions <NUM> are provided in the top ply <NUM>. At the décor embossed protrusions <NUM> with a higher height h2, the ply bonding between the top ply <NUM> and the second middle ply <NUM> is generated by means of glue which is applied towards the top surfaces of the décor embossed protrusions. Typical depths of the engraved embossing patterns are between <NUM> and <NUM>. Since the application of glue is restricted to an overall surface fraction of less than <NUM>%, preferably less than <NUM>% of the tissue product, the softness of the product can be increased.

The application of glue can also be performed on the flat ply.

The absorbency of the tissue product is between <NUM>/g and <NUM>/g.

Both the top ply <NUM> and the bottom ply <NUM> can consist of more than one single layer of tissue web material, for example of a double layer of tissue material.

As can be seen in <FIG>, the embossed protrusions <NUM> of the first middle ply <NUM> and the embossed protrusions of the adjacent top ply <NUM> are not in register with one another.

This increases the bulk and absorbency of the tissue product <NUM> because the protrusions <NUM>, 8a cannot nest one into the other which would reduce the thickness of the tissue product.

Also the provision of different densities of the embossed protrusions <NUM> of the inner ply <NUM> and the embossed protrusions 8a of the adjacent outer ply <NUM> avoid the nesting of the embossed protrusions which increases the bulk and the absorbency of the tissue product.

In <FIG>, a top view of a single sheet <NUM> of the tissue product <NUM> is shown. The sheet <NUM> according to <FIG> has a soft region <NUM> with an overall oval shape. Such a shape essentially harmonizes with the rectangular shape of individual sheets so that a relatively large surface area of each sheet can be covered by the soft region. However, the soft region can be circular or rectangular as well. The soft region <NUM> covers at least <NUM>% and up to <NUM> % of the surface area of the sheet <NUM>.

Each sheet <NUM> has a width of between <NUM> and <NUM>, preferably between <NUM> and <NUM>, and most preferably around <NUM>. The length of each sheet is between <NUM> and <NUM> and preferably around <NUM>. Such a size is a novel feature in case of a product which is designed to be a bathroom tissue. The area of each sheet ranges between <NUM><NUM> and <NUM><NUM>, and preferably between <NUM><NUM> and <NUM><NUM>.

Preferably, each sheet has a width of around <NUM> and a length of around <NUM>, and the absorbency of each sheet is preferably between <NUM>/sheet and <NUM>/sheet.

For an example sheet <NUM> with a width of around <NUM> and a length of around <NUM>, the absorbency of the sheet is more than <NUM>/sheet both for a <NUM>-ply product and a <NUM>-ply product.

Further, a décor embossing region <NUM> is provided which comprises embossed décor protrusions <NUM>. The embossed décor protrusions can be provided with different shapes, and especially different heights. Besides the embossed décor protrusions <NUM>, second embossed décor protrusions <NUM> can be provided with a smaller height than the height of the first embossed décor protrusions <NUM>.

When the embossing is in register with the dimensions of the individual sheets of the tissue product, this has the advantage that each sheet has exactly the same embossing pattern. The soft region can be arranged centered on each individual sheet, and the individual embossing patterns can be arranged such that an undesired nesting of adjacent plies can be prevented.

The soft region <NUM> is provided with micro-embossed protrusions <NUM> which are essentially not adhesively bonded to an inner ply adjacent to the top ply.

A density of such micro-embossed protrusions 8a (see <FIG>) above <NUM> dots/cm<NUM> and even up to <NUM> dots/cm<NUM> has not been feasible for a long time. Only with the option to manufacture embossing rolls using 3D-printing, it has become possible to generate embossing rolls with such a high density of embossing projections on its circumferential surface.

The claimed technology works for any densities of the embossed protrusions but it is more efficient if the density is high. It has been found that a higher density of the embossed protrusions contributes to the perceived softness of the product.

<FIG> schematically shows the device for manufacturing a product according to <FIG>. The top ply <NUM>, bottom ply <NUM>, first inner ply <NUM> and the second inner ply <NUM> are directed into the device <NUM>. As an alternative, instead of a single top ply <NUM>, two top plies <NUM> can be jointly processed leading to a <NUM>-ply product <NUM>.

The central element of the device <NUM> is the embossing roll S1 which is an engraved steel roll. The top ply <NUM> which can also be provided as a double layer is directed into the nip between the embossing roll S1 and a counter roll <NUM> in order to emboss the top ply or top plies <NUM>. After having been embossed, the first middle ply <NUM> joins the top ply. Before joining the top ply <NUM> at the embossing roll S1, the first middle ply <NUM> is micro-embossed in the nip between the engraved steel embossing roll S3 and the counter roll <NUM>.

After the top ply top plies <NUM> and the first middle ply <NUM> have been joined at the embossing roll S1, glue is applied towards the first middle ply <NUM> by means of a glue application device <NUM>. Since the embossing roll S1 has micro-embossing protrusions of a smaller height and décor embossing protrusions of a higher height, the glue is only applied towards the first middle ply <NUM> at the décor embossing protrusions with the higher height.

The second middle ply <NUM> is un-embossed and fed towards the embossing roll S1 downstream of the glue application device <NUM>. The second middle ply <NUM> is directed into the gap between the embossing roll S1 and a second embossing roll S2 which also runs against the counter roll <NUM>. The second embossing roll S2 is also an engraved steel roll with a micro-embossing pattern. In the nip between the second embossing roll S2 and the counter roll <NUM>, the bottom ply <NUM> is embossed. However, the embossing roll S2 can additionally also be provided with décor embossing protrusions. The second middle ply <NUM> joins first middle ply <NUM> and the bottom ply <NUM> and becomes sandwiched between these two.

After leaving the gap between the embossing roll S1 and the second embossing roll S2, the multi-ply structure is directed into the nip between the embossing roll S1 and an either driven or not driven marrying roll M1 where the final ply bonding takes place.

Downstream of the marrying roll M1, the multi-ply tissue product <NUM> according to the present disclosure can be directed to a perforating unit <NUM> at which the tissue product <NUM> receives perforation lines which are provided at regular intervals in a direction perpendicular to the longitudinal direction of the multi-ply tissue product <NUM>.

Downstream of the perforating unit <NUM>, the tissue product <NUM> can either be wound to a roll or folded to become a stack of individual sheets.

The embodiment according to <FIG> is very similar to that according to <FIG>. As will be appreciated, the position of the inner plies <NUM> and <NUM> between the top ply and the bottom ply is reversed to that according to <FIG>. The corresponding device <NUM> according to figure distinguishes over that according to <FIG> in that the position where the un-embossed middle ply <NUM> is directed toward the embossing roll S1 is different to that according to <FIG>. In the device <NUM> according to <FIG>, the un-embossed middle ply <NUM> is directed towards the embossing roll S1 downstream of the nip between the embossing roll S1 and the counter roll <NUM> in which the top ply <NUM> is embossed, but upstream before the micro-embossed middle ply <NUM> is joined. The application of glue at the glue application device <NUM> is towards the embossed middle ply <NUM>. As in the preceding examples of <FIG> and <FIG>, the bottom ply <NUM> joins the other plies downstream of the glue application device <NUM> and runs through the nip between the embossing roll S2 and the counter roll <NUM>, and the gap between the embossing roll S1 and the embossing roll S2. The ply bonding of all plies is carried out like in the devices as discussed above in the nip between the embossing roll S1 and the marrying roll M1.

A further possible process is shown with reference to the device <NUM> according to <FIG>. In the device <NUM> according to <FIG>, the embossed middle ply <NUM> consists of two layers which are embossed together in the nip between the embossing roll S3 and the counter roll <NUM>. Between the embossed middle plies <NUM> and the top ply <NUM>, the un-embossed middle ply <NUM> is provided. Accordingly, like in the embodiment of <FIG>, the un-embossed middle ply <NUM> is directed toward the embossing roll S1 downstream of the nip between the embossing roll S1 and the counter roll <NUM> in which the top ply <NUM> is embossed, but upstream of the position at which the micro-embossed middle plies <NUM> are joined. The application of glue at the glue application device <NUM> is towards the embossed middle plies <NUM>. As in the preceding examples of <FIG> and <FIG>, the bottom ply <NUM> joins the other plies downstream of the glue application device <NUM> and runs through the gap between the embossing roll S1 and the second embossing roll S2. The ply bonding is carried out like in the devices as discussed above in the nip between the embossing roll S1 and the either driven or not driven marrying roll M1.

<FIG> shows another product according to the present disclosure with four plies. The top ply <NUM> can be embossed as in the embodiment according to <FIG> and <FIG>. The décor embossed protrusions <NUM> have a height which is used to achieve ply-bonding of all four plies. The two middle plies are un-embossed plies. The two un-embossed middle plies can be structured plies produced by a TAD-process. The bottom ply is like that as described above with reference to <FIG>. Thus, the product is a hybrid product with two outer CWP-plies and two inner TAD-plies.

The device and its related process for manufacturing the product according to <FIG> is shown in <FIG>.

In the device <NUM> according to <FIG>, the first un-embossed middle ply <NUM> joins the top ply <NUM> downstream the position at which the top ply <NUM> is embossed in the nip between the embossing roll S1 and the counter roll <NUM> but upstream the position of the glue application device <NUM>.

The second un-embossed middle ply <NUM> joins the top ply <NUM> and the first un-embossed middle ply <NUM> downstream of the glue application device <NUM> and is directed into the gap between the embossing roll S1 and the second embossing roll S2.

The embossing roll S2 together with its co-operating counter roll <NUM> is used to emboss the bottom ply <NUM>. Thus, the bottom ply <NUM> joins the top ply <NUM> and the two un-embossed middle plies <NUM>, <NUM> in the gap between the embossing roll S1 and the embossing roll S2.

Finally, the four plies <NUM>, <NUM>, <NUM>, <NUM> are bonded together. The ply bonding is carried out like in the devices as discussed in the previous embodiments in the nip between the embossing roll S1 and the driven marrying roll M1. As in the previous embodiments, the combined ply <NUM> can be either folded or perforated in a further device downstream of the marrying roll M1.

All products according to the present disclosure have in common that they have an improved caliper, strength and softness. In the four-ply product, at least one single middle ply is un-embossed. This provides a high bulk to the resulting product and leads to a product with improved caliper, strength and softness. The advantageous provision of a micro-embossed soft region on the top ply can further make the product both aesthetically pleasing and soft.

A <NUM>-ply product was manufactured using the device according to <FIG>. The product with a basis weight of <NUM>/m<NUM> was provided with perforations to define individual sheets of bathroom tissue. The <NUM>-ply product was produced from conventional wet crepe tissue with a CWT process. The top ply was provided with a central soft region with an area of <NUM><NUM> which corresponds to <NUM>% of the sheet area of <NUM><NUM> based on a sheet length of <NUM> and a sheet width of <NUM>. The thickness of the product was <NUM>. The absorption per sheet was determined to <NUM>/sheet. The absorption values of the central soft region and the remaining region of the sheet were determined separately. The absorption value in the soft region was <NUM>/g, whereas the absorption value in the remaining region of the tissue product was <NUM>/g. These absorption values are higher than those of comparable products on the market.

Despite of an excellent water dispersibility observed, a high strength could be observed. The product had a comparably low stiffness and is perceived as a very soft product.

A <NUM>-ply product was manufactured using the device according to <FIG>. The product with a basis weight of <NUM>/m<NUM> was provided with perforations to define individual sheets of bathroom tissue. Both inner plies were TAD-plies, whereas the other plies were produced as a conventional wet crepe tissue with a CWT process. The top ply was provided with a central soft region with an area of <NUM><NUM> which corresponds to <NUM>% of the sheet area of <NUM><NUM> based on a sheet length of <NUM> and a sheet width of <NUM>. The thickness of the product was <NUM>. The absorption per sheet was determined to <NUM>/sheet. The absorption values of the central soft region and the remaining region of the sheet were determined separately. The absorption value in the soft region was <NUM>/g, whereas the absorption value in the remaining region of the tissue product was <NUM>/g. These absorption values are by far higher than those of comparable products on the market.

Surprisingly, a high strength could be observed, although the product had a comparably low stiffness and was perceived as a very soft product.

In the following, the test method used for determining the absorption capacity, basis weight and thickness will be explained.

The absorption measurements were carried out using the basket immersion method. A test sample of defined width and total mass is placed in a cylindrical basket which is dropped from a defined height over a water surface with deionized water in accordance with ISO <NUM> (conductivity ≤ <NUM>/m at <NUM> C). The time was measured from that at which the basket was dropped until the test piece had been fully wetted. The average time is the water absorption time. The amount of absorbed water is determined from the dry and wet weight of the test piece. Previous to the measurement, the test samples were conditioned a sufficient time under <NUM> and <NUM>% relative humidity (see ISO <NUM>-standard atmosphere for conditioning and testing tissue). The resulting water absorption capacity was reported in grams water per gram test piece to the nearest <NUM>/g. The method was carried out in accordance with ISO <NUM>-<NUM>:<NUM> (water-absorption time and water-absorption capacity, basket-immersion test method).

The basis weight (grammage) can be determined by a test method following the principles as set forth in standard EN ISO <NUM>-<NUM>:<NUM> for determining the basis weight. Test pieces of <NUM> cm2 are punched from the sample sheet. Test pieces are chosen randomly from the entire sample and should be free of folds, wrinkles and any other deviating distortions. The pieces are conditioned at <NUM>, <NUM> % RH (Relative Humidity) for at least <NUM> hours. A pile of <NUM> pieces is weighed on a calibrated balance. The basis weight (grammage) is the weighed mass divided by the total area <NUM><NUM> (<NUM>×<NUM><NUM>) and recorded as mean value with standard deviations.

Claim 1:
Tissue product with at least four plies made of tissue paper base sheet or nonwoven, comprising:
- a first outer ply (<NUM>) and a second outer ply (<NUM>) and at least two inner plies (<NUM>, <NUM>) between the first outer ply (<NUM>) and the second outer ply (<NUM>), wherein
- at least the first outer ply (<NUM>) comprises a décor embossing region (<NUM>); wherein
- a considerable portion of the outwardly facing main surface of the first outer ply (<NUM>) is provided with at most three soft regions (<NUM>) surrounded by the décor embossing region (<NUM>), respectively; wherein
- each soft region (<NUM>) is provided with first micro-embossed protrusions (<NUM>); and
- the décor embossing region (<NUM>) comprises first embossed décor protrusions (<NUM>); wherein
- the first micro-embossed protrusions (<NUM>) are essentially not adhesively bonded to an inner ply (<NUM>) adjacent to the first outer ply (<NUM>)
characterized in that:
- only one of the inner plies is an un-embossed ply (<NUM>), and in that
- the absorbency of the tissue product is between <NUM>/g and <NUM>/g and preferably between <NUM>/g and <NUM>/g.