Embossing system and product made thereby with both perforate bosses in the cross machine direction and a macro pattern

Abstract

An embossing system is provided for embossing at least a portion of a web comprising a first roll and at least a second roll. The first roll and second roll may define a first nip for embossing the web. At least one of the first roll and the second roll has elongated embossing elements extending substantially in the machine direction and optionally at least one of the first and second rolls has elongated embossing elements extending substantially in the cross-machine direction. At least one of the first roll and the second roll may also have perforate embossing elements extending substantially in the cross-machine direction that may or may not be elongated. The embossing elements are capable of imparting one or both of a cube embossing pattern or a perforate emboss on the web. The web may be a cellulosic fibrous web, a portion of which is lignin-rich, high coarseness fiber having generally tubular fiber configuration. In addition, the web may be creped with an undulatory creping blade.

1 . A method of embossing at least a portion of a fibrous web, including:
 providing a first roll and at least a second roll, the first roll and second roll defining a first nip for imparting a cube emboss pattern and a substantially cross-machine direction perforate emboss to the fibrous web;   imparting the cube emboss pattern to the fibrous web; and   imparting the substantially cross-machine direction perforate emboss to the fibrous web.   
     
     
         2 . The method according to  claim 1 , wherein both the first and second rolls have elongated, mated embossing elements extending substantially in the machine direction and perforate embossing elements extending substantially in the cross-machine direction, wherein the elongated embossing, mated embossing elements impart the cube emboss pattern to the fibrous web and the perforate embossing elements impart the substantially cross-machine direction perforate emboss to the fibrous web. 
     
     
         3 . The method according to  claim 1 , further including providing a cellulosic fibrous web comprising preparing an aqueous cellulosic fibrous furnish, wherein at least about 15% by weight of the fiber, based on the weight of the cellulosic fiber in the furnish, is lignin-rich, high coarseness fiber having generally tubular fiber configuration as well as an average fiber length of at least about 2 mm and a coarseness of at least about 20 mg/100 m. 
     
     
         4 . The method according to  claim 3 , wherein the lignin-rich, high coarseness generally tubular fiber is selected from at least one of APMP, TMP, CTMP, and BCTMP. 
     
     
         5 . The method according to  claim 4 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 15% by weight. 
     
     
         6 . The method according to  claim 5 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 20% by weight. 
     
     
         7 . The method according to  claim 6 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 25% by weight. 
     
     
         8 . The method according to  claim 7 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of from about 25% to about 35% by weight. 
     
     
         9 . The method according to  claim 1 , further including creping the web with an undulatory creping blade. 
     
     
         10 . The method according to  claim 3 , further including creping the web with an undulatory creping blade. 
     
     
         11 . The method according to  claim 4 , further including creping the web with an undulatory creping blade. 
     
     
         12 . An embossing roll and fibrous web combination for embossing at least a portion of a fibrous web comprising a plurality of embossing rolls defining a nip, wherein the nip is capable of imparting a cube embossing pattern to the fibrous web and of imparting a perforate emboss pattern substantially oriented in the cross-machine direction to the fibrous web wherein the cubes in the cube embossing pattern are oriented substantially in the same direction. 
     
     
         13 . The embossing system according to  claim 12 , wherein the plurality of embossing rolls defining the nip includes elongated substantially machine direction mated embossing elements and elongated substantially cross-machine direction perforate emboss elements. 
     
     
         14 . The embossing system according to  claim 13 , wherein the elongated substantially machine direction elements have a length of at least about 0.25″. 
     
     
         15 . The embossing system according to  claim 14 , wherein the elongated substantially cross-machine direction elements have a length of at least about 0.50″. 
     
     
         16 . The embossing system according to  claim 12 , wherein the fibrous web is a cellulosic fibrous web, and wherein at least about 15% by weight of the fiber, based on the weight of the cellulosic fiber in the furnish, is lignin-rich, high coarseness fiber having generally tubular fiber configuration as well as an average fiber length of at least about 2 mm and a coarseness of at least about 20 mg/100 m. 
     
     
         17 . The embossing system according to  claim 16 , wherein the lignin-rich, high coarseness generally tubular fiber is selected from at least one of APMP, TMP, CTMP, BCTMP. 
     
     
         18 . The embossing system according to  claim 17 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 15% by weight. 
     
     
         19 . The embossing system according to  claim 18 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 20% by weight. 
     
     
         20 . The embossing system according to  claim 19 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 25% by weight. 
     
     
         21 . The embossing system according to  claim 20 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of from about 25% to about 35% by weight. 
     
     
         22 . The embossing system according to  claim 12 , further comprising an undulatory creping blade capable of creping the web. 
     
     
         23 . The embossing system according to  claim 16 , further comprising an undulatory creping blade capable of creping the web. 
     
     
         24 . An embossing roll and fibrous web combination for embossing at least a portion of a fibrous web comprising a first roll and at least a second roll, the first roll and second roll defining a nip for embossing the fibrous web, wherein at least one of the first roll and the second roll has elongated embossing elements extending substantially in the machine direction and at least one of the first roll and the second roll has elongated embossing elements extending substantially in the cross-machine direction, and wherein the elongated embossing elements are capable of imparting a cube embossing pattern on the fibrous web wherein the cubes in the cube embossing pattern are oriented substantially in the same direction. 
     
     
         25 . The embossing system according to  claim 24 , wherein the elongated substantially machine direction embossing elements and elongated substantially cross-machine direction elements are on the first roll. 
     
     
         26 . The embossing system according to  claim 24 , wherein the elongated substantially machine direction embossing elements and the elongated substantially cross-machine direction elements are on both the first roll and the second roll. 
     
     
         27 . The embossing system according to  claim 26 , wherein at least one of the elongated substantially machine direction embossing elements and the elongated substantially cross-machine direction elements on both the first roll and the second roll are mated. 
     
     
         28 . The embossing system according to  claim 24 , wherein the elongated substantially machine direction elements have a length of at least about 0.25″. 
     
     
         29 . The embossing system according to  claim 28 , wherein the elongated substantially cross-machine direction elements have a length of at least about 0.50″. 
     
     
         30 . The embossing system according to  claim 24 , wherein at least one of the first roll and the second roll further includes embossing elements for embossing and perforating the fibrous web, and wherein at least a portion of the embossing elements for embossing and perforating the fibrous web are substantially oriented in the cross-machine direction. 
     
     
         31 . The embossing system according to  claim 30 , wherein substantially all of the embossing elements for embossing and perforating the fibrous web are substantially oriented in the cross-machine direction. 
     
     
         32 . The embossing system according  claim 31 , wherein all of the embossing elements for embossing and perforating the fibrous web are substantially oriented in the cross-machine direction. 
     
     
         33 . The embossing system according to  claim 30 , wherein the elongated substantially machine direction embossing elements, the elongated substantially cross-machine direction elements, and the embossing elements for embossing and perforating the fibrous web are on the first roll. 
     
     
         34 . The embossing system according to  claim 30 , wherein the elongated substantially machine direction embossing elements, the elongated substantially cross-machine direction elements, and the embossing elements for embossing and perforating the fibrous web are on both the first roll and the second roll. 
     
     
         35 . The embossing system according to  claim 30 , wherein the one or more of the elongated substantially machine direction embossing elements, the elongated substantially cross-machine direction elements, and the embossing elements for embossing and perforating the fibrous web on both the first roll and the second roll are mated. 
     
     
         36 . The embossing system according to  claim 24 , further including a third roll having embossing elements and a fourth roll having embossing elements, wherein at least a portion of the embossing elements of the third roll and the fourth roll are substantially oriented in the cross-machine direction. 
     
     
         37 . The embossing system according to  claim 36 , wherein substantially all of the embossing elements on the third roll and the fourth roll are substantially oriented in the cross-machine direction. 
     
     
         38 . The embossing system according to  claim 37 , wherein all of the embossing elements on the third roll and the fourth roll substantially oriented in the cross-machine direction. 
     
     
         39 . The embossing system according to  claim 24 , further including at least a third roll having embossing elements, wherein the embossing elements of the third roll are for embossing and perforating the fibrous web, and wherein at least a portion of the embossing elements of the third roll are substantially oriented in the cross-machine direction. 
     
     
         40 . The embossing system according to  claim 39 , wherein substantially all of the embossing elements of the third roll are substantially oriented in the cross-machine direction. 
     
     
         41 . The embossing system according to  claim 40 , wherein all of the embossing elements of the third roll are substantially oriented in the cross-machine direction. 
     
     
         42 . The embossing system according to  claim 24 , wherein the fibrous web is a cellulosic fibrous web, and wherein at least about 15% by weight of the fiber, based on the weight of the cellulosic fiber in the furnish, is lignin-rich, high coarseness fiber having generally tubular fiber configuration as well as an average fiber length of at least about 2 mm and a coarseness of at least about 20 mg/100 m. 
     
     
         43 . The embossing system according to  claim 42 , wherein the lignin-rich, high coarseness generally tubular fiber is selected from at least one of APMP, TMP, CTMP, BCTMP. 
     
     
         44 . The embossing system according to  claim 43 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 15% by weight. 
     
     
         45 . The embossing system according to  claim 44 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 20% by weight. 
     
     
         46 . The embossing system according to  claim 45 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 25% by weight. 
     
     
         47 . The embossing system according to  claim 46 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of from about 25% to about 35% by weight. 
     
     
         48 . The embossing system according to  claim 24 , further including an undulatory creping blade capable of creping the web. 
     
     
         49 . The embossing system according to  claim 30 , further including an undulatory creping blade capable of creping the web. 
     
     
         50 . The embossing system according to  claim 36 , further including an undulatory creping blade capable of creping the web. 
     
     
         51 . The embossing system according to  claim 39 , further including an undulatory creping blade capable of creping the web. 
     
     
         52 . The embossing system according to  claim 42 , further including an undulatory creping blade capable of creping the web. 
     
     
         53 . A method of embossing at least a portion of a fibrous web, including providing a cellulosic fibrous web to at least a first nip, wherein the first nip imparts a cube emboss pattern to the web and a substantially cross-machine direction perforate emboss pattern to the web. 
     
     
         54 . The method according to  claim 53 , wherein providing a cellulosic fibrous web further comprises preparing an aqueous cellulosic fibrous furnish, wherein at least about 15% by weight of the fiber, based on the weight of the cellulosic fiber in the furnish, is lignin-rich, high coarseness fiber having generally tubular fiber configuration as well as an average fiber length of at least about 2 mm and a coarseness of at least about 20 mg/100 m. 
     
     
         55 . The method according to  claim 54 , wherein the lignin-rich, high coarseness generally tubular fiber is selected from at least one of APMP, TMP, CTMP, BCTMP. 
     
     
         56 . The method according to  claim 55 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 15% by weight. 
     
     
         57 . The method according to  claim 56 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 20% by weight. 
     
     
         58 . The method according to  claim 57 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of at least about 25% by weight. 
     
     
         59 . The method according to  claim 58 , wherein the lignin-rich, high coarseness, generally tubular fiber is BCTMP having a lignin content of from about 25% to about 35% by weight. 
     
     
         60 . The method according to  claim 53 , further including creping the web with an undulatory creping blade. 
     
     
         61 . The method according to  claim 54 , further including creping the web with an undulatory creping blade. 
     
     
         62 . An embossing system for embossing at least a portion of a fibrous web comprising:
 a first roll; and   at least a second roll, the first roll and second roll defining a first nip for embossing the fibrous web,   wherein at least one of the first roll and the second roll has elongated embossing elements extending substantially in the machine direction and at least one of the first roll and the second roll has elongated embossing elements extending substantially in the cross-machine direction, wherein the embossing elements are capable of imparting a cube embossing pattern on the fibrous web, wherein the cube's z-axis is oriented substantially parallel to the cross-machine direction of the web, and   wherein at least one of the first roll and the second roll includes embossing elements for embossing and perforating the fibrous web, and wherein at least a portion of the embossing elements for embossing and perforating the fibrous web are substantially oriented in the cross-machine direction.   
     
     
         63 . The embossing system according to  claim 62 , wherein the substantially machine direction elongated embossing elements, the substantially cross-machine direction elongated embossing elements, and the embossing elements for embossing and perforating the fibrous web are on both the first roll and the second roll. 
     
     
         64 . (canceled)