Multi-ply absorbent paper product having impressed pattern

Abstract

A multi-ply tissue includes a first cellulosic embossed ply having an emboss pattern applied over a portion of its surface and a second cellulosic embossed ply of tissue. The first ply is contact laminated to the second ply so that the primary adhesion between the plies of tissue is the result of contact between cellulosic fibers. The first and second plies contact one another in contact-areas, with the contact areas between the first and second plies defining compliant voids. The contact areas between the first ply and the second ply are elongated and/or rounded contact areas. A method of forming a multi-ply tissue involves conveying a base sheet through a nip between an impression roll and a pattern roll to produce an embossed base sheet having a back side possessing projections, applying adhesive to the back side of the embossed base sheet at spaced apart locations, and applying a flat backing sheet to the back side of the embossed base sheet so that the backing sheet adheres to the back side of the embossed base sheet at said spaced apart locations. A method of producing an embossed tissue involves successively conveying a base sheet through a nip between a first impression roll and a pattern roll, and conveying the base sheet through another nip between the pattern roll and a second impression roll, wherein the second impression roll is made of rubber having a lower hardness than the rubber from which the first impression roll is made.

1 . A method of forming a two-ply tissue comprising: 
 producing a first ply of tissue having an emboss pattern;    producing a second ply of tissue having an emboss pattern, the first ply being more heavily embossed than the second ply;    resting the first and second plies together to contact laminate the first ply to the second ply with contact areas between the first and second plies, the contact areas being elongated or gently rounded.    
   
   
       2 . The method according to  claim 1 , wherein the emboss patterns on the first ply and the second ply are formed by emboss elements having an aspect ratio greater than one.  
   
   
       3 . The method according to  claim 1 , wherein the emboss patterns on the first ply and the second ply are formed by emboss elements having an aspect ratio greater than 5.  
   
   
       4 . The method according to  claim 1 , including preconditioning the first ply and the second ply before embossing through use of heat and moisture.  
   
   
       5 . The method according to  claim 1 , including preconditioning the first ply and the second ply before embossing through use of steam.  
   
   
       6 . A method of producing an embossed tissue comprising: 
 conveying a base sheet through a nip between a first impression roll made of rubber and a pattern roll to push portions of the base sheet into indented portions of the pattern roll;    conveying the base sheet through a nip between the pattern roll and a second impression roll made of rubber having a lower hardness than the rubber from which the first impression roll is made to push the portions of the base sheet further into the indented portions of the pattern roll to produce an embossed tissue.    
   
   
       7 . The method according to  claim 6 , including conveying the base sheet between the first impression roll and another impression roll prior to conveying the base sheet through the nip between the first impression roll and the pattern roll.  
   
   
       8 . A method of forming a two-ply tissue comprising: 
 conveying a base sheet through a nip between an impression roll and a pattern roll to emboss a pattern on the base sheet, the engagement of the impression roll with the pattern roll producing an embossed base sheet having a back side possessing projections produced by the pattern roll; and    apply a flat backing sheet to the back side of the embossed base sheet by contact lamination to cause the backing sheet to adhere to the back side of the embossed base sheet and thereby form a two-ply tissue.    
   
   
       9 . The method according to  claim 8 , wherein the base sheet and the backing sheet are conveyed at different speeds.  
   
   
       10 . The method according to  claim 8 , wherein the projections on the embossed base sheet include projections with differing heights.