HK1100784A - Three-dimensional product with dynamic visual impact - Google Patents

Description

Three-dimensional product with dynamic visual effect

Technical Field

The present invention relates to three-dimensional products having a structure that provides an improved aesthetic image with dynamic visual effects.

Background

It is well known in the art to generate three-dimensional images on the surface of a product to enhance the aesthetic appeal of the product. In particular, the production of such images on the surface of paper products by embossing of the paper products has been carried out for many years. It is also known that embossing makes those paper products more absorbent, softer and bulkier.

The idea of having an image change depending on the angle of view is also not new. The use of lenticular lenses or diffraction gratings in combination with multiple images to create holograms has fully developed this idea. However, the use of such lenses or gratings is not only expensive but often impractical for more aesthetic improvements to simpler products.

The present invention relates to a specific set of features of a three-dimensional structure that produces an image that changes features with the angle of observation without the addition of a film, lens or grating.

Disclosure of Invention

The invention relates to a three-dimensional product comprising a structure having a first surface and a z-direction perpendicular to the first surface, the structure further comprising a base, a plurality of raised protrusion areas raised at least about 300 μm above the base of the structure, and a plurality of connecting elements, each connecting element terminating in a raised protrusion and each connecting element being raised above the base of the structure in the z-direction and being at least partially recessed from the raised protrusions in the z-direction, wherein a connecting element connects two raised protrusion areas; the plurality of raised protrusion areas and the plurality of connecting elements together form a pattern comprising at least a first sub-pattern area and a second sub-pattern area; wherein the first sub-pattern region comprises a first set of parallel rows of raised protrusion regions and connecting elements and a second set of parallel rows of raised protrusion and connecting elements that are not parallel to the first set of parallel rows, and the first sub-pattern region is structurally distinguishable from the second sub-pattern region.

Drawings

FIG. 1 is a schematic view of one embodiment of a three-dimensional product having a structure that provides a dynamic visual image on a surface of the product in accordance with the present invention. FIGS. 1A-A, 1B-B and 1C-C are cross-sectional views of the three-dimensional product of FIG. 1.

Fig. 2 is a schematic view of another embodiment of a three-dimensional product having a structure that provides a dynamic visual image on a surface of the product in accordance with the present invention. FIGS. 2A-A, 2B-B and 2C-C are cross-sectional views of the three-dimensional product of FIG. 2.

Fig. 3 is a top view of two embodiments of sub-pattern regions of protrusions and connecting elements of the present invention.

Fig. 4 is a top view of two other embodiments of sub-pattern regions of protrusions and connecting elements of the present invention.

Fig. 5 is a top view of a pattern of protrusions for use in one embodiment of the present invention with a pattern of connecting elements illustrating first and second sub-patterns of the overall pattern.

Figure 6 is a representation of a deep nested embossing pattern for creating one embodiment of the three-dimensional product of the present invention.

FIG. 7 is a photograph of a three-dimensional paper product illustrating an image representation when viewed in one direction.

FIG. 8 is a photograph of the same three-dimensional paper product from FIG. 7 illustrating a second communicated image when viewed in a direction rotated 90 from the direction in FIG. 7 about the z-direction of the product.

Fig. 9 is a side view of the gap between two engaged embossing rolls of a deep nested embossing process that can be used to manufacture one embodiment of the present invention.

Detailed Description

The invention relates to a three-dimensional product with an optically dynamic image. Optically dynamic images are such images that convey more than one image to the eyes of a person, depending on the direction from which the product is viewed and/or depending on the angle and intensity of the illumination.

The present invention is a three-dimensional product 10 comprising a structure 15 having a first surface 11 and a z-direction perpendicular to the first surface 11. The structure 15 further includes a base 50, a plurality of raised protrusion areas 20 protruding at least about 300 μm beyond the base of the structure, and a plurality of connecting elements 30, each connecting element 30 terminating in a raised protrusion 20, and each connecting element 30 protruding in the z-direction beyond the base 50 of the structure 15 and at least partially recessed from the raised protrusions 20 in the z-direction. The connecting element 30 connects the two raised protrusion areas 20. The plurality of raised protrusion areas 20 and the plurality of connecting elements 30 together form a pattern comprising at least a first sub-pattern area 60 and a second sub-pattern area 61. The first sub-pattern region 60 comprises a first set of parallel rows of raised protrusion areas 20 and connecting elements 30 and a second set of parallel rows of raised protrusion areas 20 and connecting elements 30 that are not parallel to the first set of parallel rows. The first sub-pattern region 60 is structurally distinguishable from the second sub-pattern region 61.

The structure of the present invention may vary in size depending on the intended use for the dynamic image conveyed by the present invention. It may be relatively small, such as on the surface of a security card, or it may be relatively large, such as a pattern on a wall. The present invention contemplates arbitrary adoption on the three-dimensional structure image of any product intended to have a dynamic visual image.

Fig. 1 and 2 depict two embodiments of a three-dimensional product 10 of the present invention. The product 10 includes a structure 15 having a first surface 11 and a second surface 12. The product may be any product having a surface that can be made aesthetically more appealing by adding a visually dynamic image to its surface. Without being limited in any way, these products may be plastic card products, paper products, wallpaper or building elements such as walls or ceilings. The product 10 may be manufactured by any method known in the appropriate industry for producing three-dimensional products. This includes manufacturing the product in the form of a sheet or roll, in the form of a stamped or molded blank, or in the form of an assembled product from individual parts.

The three-dimensional product 10 of the present invention comprises a structure 15 having a first surface 11 comprising protruding regions 20 and connecting elements 30 arranged in a pattern that produces a visually dynamic image. The surface 11 is generally flat and therefore has two dimensions: length and width. However, it is possible that the surface is concave or convex, or otherwise slightly irregular, cylindrical or spherical. In fact, the surface may be any mixture of these orientations. However, at any point on the surface, the z-direction is perpendicular to the surface of the product at the point in question. When viewed from one side of the surface, the z-direction is generally understood to be the direction out of the surface of the product (positive z-direction) or into the surface of the product (negative z-direction), whether the surface is best represented by rectangular, cylindrical or spherical coordinates at a given point.

The structure 15 of the product comprises a base 50, which is the part of the structure that is the furthest away from the viewer in the negative z-direction. The seat 50 may be a plurality of points or flat areas located in the valley between the protrusion 20 and the connecting element 30. It is not necessary that all of the local pedestal regions be exactly at the same z-dimension location in the entire pattern or sub-pattern region.

The structure 15 of the product 10 also includes a plurality of raised protrusion areas 20 or protrusions. The raised protrusion areas 20 are the portions of the structure formed in discrete peaks or plateaus above the base 50 of the structure 15. The actual shape of the protruding top area may be circular, oval, square, rectangular or any other shape. The raised protrusion areas are located at a distance or "height" in the positive z-direction of at least about 300 μm, preferably at least about 650 μm, more preferably at least about 1000 μm, and most preferably at least about 1250 μm. When the Height of the protrusions is less than 5000 μm, the Height can be measured using a GFM Primos Optical Profiler with Primos Height Test, as described herein under "Test methods".

The structure 15 further comprises a plurality of connecting elements 30. Each connecting element 30 is a portion of a generally linear structural material, terminating at its distal end in a raised projection region 20 when viewed from above. Thus, each connecting element 30 extends between two raised protruding areas 20. The connecting elements 30 project above the base in the z-direction, but at least a portion of the span of individual connecting elements 30 is recessed below the top of the projections 20 to which they are connected. Features recessed below the top of the protrusion include those in which the location of the end of the connecting element is at the same height as the top of the protrusion, as shown in fig. 1. The connecting element may be of any cross-sectional shape when viewed from the end.

The protrusions 20 and connecting elements 30 of the three-dimensional product may be arranged to form a pattern of multiple parallel rows of alternating protrusions and connecting elements. The term "row" is used to refer to a set of uninterrupted protrusions and connecting elements that connect those elements into a sequence or string of elements. The rows may be straight, curved, or a mixture thereof. By "parallel rows" is meant that two or more of these rows of protrusions and connecting elements extend alongside one another, typically maintaining a constant spacing between the two rows. In one embodiment, the multiple parallel rows may be two or more linear rows extending in parallel in a rectangular orientation. In another embodiment, the multiple parallel rows may be two of a plurality of curved rows, each of the curves following a similar curved path with a generally constant spacing from row to row.

The general structure of one of these rows is shown in FIGS. 1A-A, 1B-B, 2A-A and 2B-B, which are cross-sectional profiles along the row. The length of the protrusion is denoted P. The length of the connecting element is denoted by a or B and the depth of the recess of the connecting element from the protrusion is denoted by a or B. P does not necessarily have the same value along all rows. The cross-section of the three-dimensional structure is shown as a straight line between the protrusion 20 and the base 50, which is shown in fig. 1C-C and 2C-C. The distance between the protrusions in this direction depends on the desired size of the selected protrusion and the row of connecting elements. The height of the protrusion beyond the base, denoted by h, is greater than about 300 μm.

The product comprises at least two sub-pattern areas 60 and 61, wherein a first sub-pattern area 60 is structurally distinct from a second sub-pattern area 61. The sub-pattern regions may be distinguishable in any manner such that the regions appear different to a viewer. The structural differences may include having protrusions 20 and connecting elements 30 in the first sub-pattern region 60 and no protrusions and connecting elements in the second sub-pattern region 61. The distinguishing may also include the first sub-pattern region being rotated to obtain a second sub-pattern region, wherein the sets of parallel rows within each sub-pattern region are not parallel to each other. Other structural differences may also include obtaining a second pattern by modification of the first pattern; a change in magnification, zooming in or out of the pattern from one area to a second area; having a completely different pattern in one region than in a second region; or a mixture of these with or without rotation. Preferably, the first sub-pattern region 60 comprises at least two sets of parallel rows of alternating protrusions 20 and connecting elements 30, and the second sub-pattern region 61 comprises at least two sets of parallel rows of alternating protrusions 20 and connecting elements 30 that are non-parallel to the sets of parallel rows within the first sub-pattern region 60. Fig. 3 and 4 illustrate these sets of parallel rows with rows 65 and 66 in sub-pattern region 60 and rows 67, 68 and optional row 69 in sub-pattern region 61.

Within the sub-pattern region, without being limited by theory, it is believed that these specific combinations of structural elements alter the visual effect of the various patterns. For example, when one of a plurality of sets of parallel rows of alternating protrusions and connecting elements is viewed at an angle in a direction across the row in overhead lighting, the height difference between the protrusions and connecting elements can be minimized in the eye compared to the height difference in the valleys from the top of the row to the base formed by the protrusions and connecting elements. Under these conditions, the linear character of the line dominates and the specific structure appears to the eye more like a line. In contrast, when the parallel rows are viewed at an angle along the direction of the rows under overhead lighting, the height difference between the protrusions and connecting elements is disturbed by the linear orientation of the rows to the eyes, making it appear that the rows are softened or in some cases disappear, such that the other elements of the pattern become more prominent to the eyes.

This change in the dominant and subdued nature of the linearity of the rows may produce a dynamically changing image to the eye when a second set of parallel rows of protruding and connecting elements are embedded in the pattern of sub-pattern regions. The dominant linearity of the first set of elements at a combination of illumination angle and viewing angle renders an image in the form of those elements. However, the dominant linearity of the second set of elements at the second combination of illumination angle and viewing angle renders an image in the form of those second row elements.

By repeating the sub-pattern regions throughout the entire pattern, the visual dynamic effect on the surface of the three-dimensional product may be enhanced. The repeating pattern may be in any direction across the surface of the product so that it is regularly repeated in a pattern along the length of the product, along the width of the product, or both. The repeating pattern may alternatively be a random repetition of sub-pattern areas or a combination of sub-pattern areas on the surface of the product.

As a result of these three-dimensional patterns of protruding and connecting elements, it is now possible to create a product that conveys more than one expressive image by simply rotating the viewing angle of the product or changing the illumination angle or intensity. Rotation of the viewing angle may include rotating the product about its z-direction, changing the viewing angle between the z-coordinate and the viewing line, a change in surface topography (e.g., the product changes from a flat product to a cylindrical roll), or a combination of these. Such an example can be seen in the photographs of the tissue-towel embodiment shown in fig. 7 and 8, where two disparate images can be seen to be present on the same product roll by simply rotating the product roll 90 ° about the z-direction of the product. These three-dimensional patterns can be used to create multiple representations of an image by rotating a rolled product about its cylindrical axis when viewing the product from a position orthogonal to the product, i.e., along the z-coordinate of the product.

Detailed description of the preferred embodiments

As described above, the three-dimensional product of the present invention may vary in size depending on the intended use of the dynamic image expressed by the present invention. It may be relatively small, such as on the surface of a security card, or it may be relatively large, such as a pattern on a wall. The present invention contemplates arbitrary adoption on the three-dimensional structure image of any product intended to have a dynamic visual image. As such, any material may be employed to form the structure for the three-dimensional product of the present invention. Similarly, any method for creating three-dimensional structures may be used to fabricate the structural elements of the present invention to create dynamic visual images. Without being limited thereto, the desired method may be determined according to the size, durability and intended use of the product.

Possible materials for the structure may include any material, including but not limited to paper, polymeric or plastic films, cloth or fabrics, woven materials, nonwoven materials, laminates, metal foils such as aluminum foil, coated papers such as wax or grease proof papers, and combinations thereof. The properties of the selected web material may include, but are not limited to, a combination of the following properties or a degree thereof: porous, non-porous, microporous, gas or liquid permeable, impermeable, hydrophilic, hydrophobic, hygroscopic, oleophilic, oleophobic, high critical surface tension, low critical surface tension, surface pre-textured, elastically yieldable, plastically yieldable, electrically conductive, and electrically insulating.

Useful plastic films include, but are not limited to, polyethylene, ethylene copolymers such as Ethylene Vinyl Acetate (EVA), polypropylene, Polyester (PET), polyvinyl chloride (PVC), polyvinylidene chloride and copolymers (PVDC), latex structures, polystyrene, nylon, and the like. Polyolefins are generally preferred due to their low cost and ease of shaping. Preferred material gauges are about 0.0001 mm (0.0025mm) to about 0.25mm (0.010in), more preferred gauges are about 0.005mm (0.0002in) to about 0.051mm (0.002in), and even more preferred gauges are about 0.0076mm (0.0003in) to about 0.025mm (0.001 in). A preferred material is High Density Polyethylene (HDPE) of nominal thickness 0.0178mm (0.0007 in).

For some embodiments of three-dimensional products having the structure of the present invention, the height of the raised protrusion areas 20 above the base 50 may be in the range of about 300 μm to about 2500 μm, preferably in the range of about 650 μm to about 1500 μm. The protrusions may be rounded with a diameter, P, greater than about 500 μm, preferably in the range of about 500 μm to about 4000 μm, more preferably about 1000 μm to about 2500 μm. The lengths A and B of the connecting elements are in the range of about 1000 μm to about 12000 μm, preferably in the range of about 1500 μm to about 6000 μm, more preferably about 1500 μm to about 4500 μm. The depth a and b to which connecting element 30 is recessed from raised protrusion area 20 may be greater than about 150 μm, preferably in the range of about 200 μm to a value about equal to 95% of protrusion height h, more preferably in the range of about 300 μm to about 90% of h, and most preferably in the range of about 300 μm to about 1400 μm.

In one embodiment, the three-dimensional product is a tissue-towel paper product. The phrase "tissue-towel paper product" as used herein refers to products generally comprising a tissue or towel process, including but not limited to conventional felt-pressed or wet-pressed tissues; pattern densified tissue; ventilating and drying the paper; and high bulk, uncompacted tissue. Non-limiting examples of tissue-towel paper products include paper towels, facial tissues, toilet tissue, napkins, and the like.

The structure of the tissue-towel paper product embodiment may comprise one or more plies of fiberboard made by any tissue process known in the art. The term "ply" or "layer" refers to a single ply of board having formed fibers for use as a tissue product. A ply as used herein may comprise one or more wet laid layers. When more than one wet-laid layer is used, they need not be made of the same fibrous structure. Further, the layers may be uniform or non-uniform within the layer. The actual make-up of the tissue plies is determined by the desired benefit of the final paper product. Tissue paper is an arrangement of fibers produced in any typical paper machine known in the art for producing tissue-towel plies. Applicable wood pulps include chemical wood pulps, such as Kraft, sulfite, and sulfate wood pulps, as well as mechanical wood pulps, including, for example, groundwood, thermomechanical wood, and chemically modified thermomechanical wood pulp. Also applicable to the present invention are fibers derived from recycled paper, which may contain any or all of the above categories, as well as other non-fibrous materials, such as fillers and binders used to facilitate the initial papermaking. In addition to the above, fibers and/or filaments made from polymers, particularly hydroxyl polymers, may also be used in the present invention. Non-limiting examples of suitable hydroxyl polymers include polyvinyl alcohol, starch derivatives, chitosan derivatives, cellulose derivatives, gums, arabinans, galactans, and mixtures thereof.

Embodiments of the tissue-towel paper product can include any tissue paper product known in the industry. These embodiments can be made according to the following U.S. patents: 4,191,609 to Trokhan on 3/4/1980, 4,300,981 to Carstens on 11/17/1981, 4,191,609 to Trokhan on 3/4/1980, 4,191,609 to Johnson on 4/30/1985, 4,514,345 to Johnson et al, 4,528,239 to Trokhan on 7/9/1985, 4,529,480 to Trokhan on 7/16/1985, 4,529,480 to Trokhan on 1/20/1987, 5,245,025 to Trokhan et al on 9/1993, 5,245,025 to Trokhan et al on 14/1994, 5,275,700 to Trokhan on 1/4/1994, 5,328,565 to Rasch on 7/12/1994, 5,334,289 granted to Trokhan et al on 8/2 of 1994, 5,364,504 granted to Smurkowski et al on 11/15 of 1995, 5,527,428 granted to Trokhan et al on 6/18 of 1996, 5,556,509 granted to Trokhan et al on 9/17 of 1996, 5,628,876 granted to Ayers et al on 5/13 of 1997, 5,629,052 granted to Trokhan et al on 5/13 of 1997, 5,637,194 granted to Ampulski et al on 6/10 of 1997, 5,411,636 granted to Hermans et al on 5/2 of 1995, and EP 677612 published on Wendt et al on 18 of 10/10 of 1995.

The base of the tissue may be through-air dried or conventionally dried. Optionally, it may be foreshortened by creping or by wet microcontraction. Examples of creping and/or wet microcontraction are disclosed in the following commonly assigned U.S. patents: 6,048,938 granted to Neal et al on 11/4/2000, 5,942,085 granted to Neal et al on 24/8/1999, 5,865,950 granted to Vinson et al on 2/1999, 4,440,597 granted to Wells et al on 4/3/1984, 4,191,756 granted to Sawdai on 5/4/1980, and 09/042,936 in U.S. patent nos. filed on 17/3/1998.

Conventionally pressed tissue paper and methods of making such paper are known in the art. See commonly assigned U.S. patent application 09/997,950 filed on month 11 and 30 of 2001. One suitable tissue-towel paper is pattern densified tissue paper characterized by having a relatively high bulk area of relatively low fiber density and an array of densified areas of relatively high fiber density. Alternatively, the high packing volume region is characterized as a shoe region. Alternatively, the dense region is referred to as the joint region. The densified regions may be discontinuously spaced in the high-bulk region or fully or partially interconnected in the high-bulk region. Preferred methods for making patterned densified tissue webs are disclosed in U.S. patent nos. 3,301,746 to Sanford and Sisson at 31/1/1967, 3,974,025 to Ayers at 8/10/1976, 4,191,609 at 3/4/1980, and 4,637,859 at 20/1/1987; U.S. Pat. No. 3,301,746 to Sanford and Sisson, 31/1967, Salvucci, 5/21/1974, U.S. Pat. No. 3,821,068 to Jr. et al, Ayers, 8/10/1976, U.S. Pat. No. 3,974,025 to Friedberg et al, 3/30/1971, U.S. Pat. No. 3,573,164 to Friedberg et al, Amneus, 10/21/1969, U.S. Pat. No. 3,473,576 to Trokhan, 12/16/1980, U.S. Pat. No. 4,239,065 to Trokhan, and U.S. Pat. No. 4,528,239 to Trokhan, 7/9/1985.

Uncompacted, non-pattern densified tissue structures are also contemplated to be within the scope of the present invention and are described in U.S. patent 3,812,000 to Joseph l.salvucci, jr. and Peter n.yiannos on 5/21 of 1974 and U.S. patent 4,208,459 to Henry e.becker, Albert l.mcconnell and Richard Schutte on 6/17 of 1980.

Tissue embodiments can also be made from uncreped tissue. As used herein, the term "uncreped tissue" refers to tissue that has not been press dried, most preferably dried by through-air drying. The resulting through-air dried web is pattern densified such that the higher density regions are dispersed in high bulk regions, comprising pattern densified tissue paper wherein the higher density regions are continuous and the high bulk regions are discrete. Techniques for making uncreped tissue paper in this manner have been proposed in the prior art. For example, European patent application 0677612A 2 to Wendt et al, published at 18.10.1995, European patent application 0617164A 1 to Hyland et al, published at 28.9.1994, and U.S. patent 5,656,132 to Farrington et al, published at 12.8.1997.

The papermaking fibers used in the present invention typically comprise fibers derived from wood pulp. Other cellulosic fibrous pulp-containing fibers, such as cotton linters, bagasse, and the like, can be used and are intended to be included within the scope of the present invention. Synthetic fibers, such as rayon, polyethylene, and polypropylene fibers, may also be used in combination with natural cellulosic fibers. An exemplary polyethylene fiber that can be used is Pulpex available from Hercules, Inc. (Wilmington, DE)^。

Other materials may be added to the aqueous papermaking furnish or the embryonic web to impart other desirable characteristics to the product or to modify the papermaking process. See, e.g., U.S. patent 5,221,435 to Smith at 6/22/1993; U.S. Pat. No. 3,700,623, published 24/10 in 1972, and U.S. Pat. No. 3,772,076, published 13/11 in 1973, both issued to Keim; U.S. patent 4,981,557 to Bjorkquist, published on 1/1991; us patent 4,011,389 issued to Langdon et al on 8/3/1977; and U.S. patent 5,611,890 issued to Vinson et al on 18/3/1997.

Another class of suitable substrates for use in the process of the present invention are nonwoven webs comprising synthetic fibers. Examples of such substrates include, but are not limited to, textiles (e.g., woven and nonwoven fabrics, etc.), other nonwoven substrates, and paper-like products comprising synthetic or multicomponent fibers. Representative examples of other preferred matrices can be found in the following patents: U.S. patent 4,629,643 to Curro et al at 16.12.1986, U.S. patent 4,609,518 to Curro et al at 2.9.1986, european patent application EP a 112654 in the name of Haq, co-pending U.S. patent application 10/360038 in the name of Trokhan et al at 6.2.2003, co-pending U.S. patent application 10/360021 in the name of Trokhan et al at 6.2.2003, co-pending U.S. patent application 10/192,372 in the name of Zink et al at 10.7.2002, and co-pending U.S. patent application 09/089,356 in the name of Curro et al at 20.12.2000.

The structure of the base 50, projections 20 and connecting elements 30 of the tissue-towel paper product embodiment for use in the products of the present invention can be formed in any paper forming process known in the industry. These methods include, but are not limited to, wet forming during papermaking or embossing of finished paper. One suitable method of forming the three-dimensional mechanism of the present invention is deep nested embossing. Any deep nested embossing process known in the industry may be used. Fig. 9 illustrates the nip of two embossing rolls wherein a deep nested pattern is formed into any material to be embossed. The structure 15 is embossed in the gap 500 between the two embossing rolls 100 and 200. The embossing roll may be made of any material used to make such rolls including, but not limited to, steel, rubber, elastomeric materials, and combinations thereof. Each embossing roll 100 and 200 has a combination of embossing teeth 110 and 210 and gaps 120 and 220. Each of the embossing teeth has a tooth base 140 and a tooth flank 150. The surface pattern of the rolls, i.e., the design of the various teeth and gaps, may be any design desired for the product, however for a deep nested embossing process, the roll designs should be matched such that the tooth flanks of one roll 130 extend into the gaps of the other roll beyond the tooth flanks of the other roll 230 to create a depth of engagement 300. Depth of engagement 300 is the distance between nested tooth faces 130 and 230. The depth of engagement 300 used to make the paper product of the present invention may be in the range of about 1016 μm (0.04in) to about 2032 μm (0.08in), and preferably about 1270 μm (0.05in) to about 1778 μm (0.07in), such that the surface of the fibrous structure of a sheet of tissue paper product is formed with an embossment height of at least 300 μm.

Embodiment 1

One fibrous structure useful in the tissue-towel paper products of the present invention is a through-air-dried (TAD), differential density structure as described in U.S. patent No. 4,528,239. Such a structure may be formed, for example, by the following method.

A pilot scale fourdrinier, through-air-dried paper machine can be used to make the paper web. A slurry of papermaking fibers is pumped to a headbox at a consistency of about 0.15%. The slurry consisted of about 60% Northern Softwood Kraft fiber, refined to about 500mL of canadian standard freeness and about 40% unrefined Southern Softwood Kraft fiber. The fiber slurry contained a cationic polyamine-epichlorohydrin wet strength resin at a concentration of about 11.3kg (25lb. per ton) of dry fiber per 907kg, and a carboxymethyl cellulose at a concentration of about 2.9kg (6.5lb per ton) of dry fiber per 907 kg.

Dewatering was carried out on fourdrinier wire and was facilitated by vacuum boxes. The wire is of a configuration having 84 machine direction filaments and 78 cross direction filaments per inch, such as a product available from Albany International under the designation 84X 78-M.

The wet laid web was transferred from the fourdrinier wire to a TAD carrier fabric in a pattern having a fiber consistency of about 22% at the time of transfer. The wire speed is about 6% faster than the carrier fabric so that wet shortening of the web occurs upon transfer. The sheet side of the carrier fabric consisted of a continuous, patterned web of photosensitive resin, the pattern containing about 330 deflection tubes per inch. The deflection conduits are arranged in a biaxial staggered configuration with the polymer mesh covering about 25% of the surface area of the carrier fabric. The polymer resin was supported and attached to a braided support member consisting of 70 machine direction filaments and 35 cross direction filaments per inch. The web of photosensitive resin was raised about 0.02cm (0.008 ") above the support member.

After the TAD dryer has been operated for approximately one 450F action, the web has a consistency of about 65% prior to transfer to the Yankee dryer. An aqueous solution of creping adhesive consisting of polyvinyl alcohol was applied to the Yankee dryer surface by a spray applicator at a rate of about 2.3kg (5lb per ton) of product per 907 kg. The Yankee dryer was operated at a speed of about 3.05m/s (600 fpm). The fiber consistency was increased to about 99% prior to dry creping the web with a doctor blade. The doctor blade was beveled at about 25 degrees and positioned relative to the Yankee dryer to provide an impact angle of about 81 degrees. The Yankee dryer operates at about 157 ℃ (315 ° f) and the Yankee hood operates at about 176 ℃ (350 ° f). The dried, creped web was passed between two calender rolls running at 2.7m/s (540fpm) resulting in a net 6% foreshortening through the creped web.

The paper is also subjected to a deep embossing process to form the three-dimensional structures of the present invention. The two embossing rolls are engraved with complementary, nested protrusions in the pattern shown in fig. 6, wherein the blue dots represent the embossing roll protrusions on the first embossing roll and the red dots represent the embossing roll protrusions on the second embossing roll. The protrusions are conical in shape with a face diameter of about 0.16cm (.063 ") and a base diameter of about 0.31cm (0.121"). The height of the protrusions on each roll was about 0.22cm (0.085 "). The connecting elements of the structure in this embodiment are formed by reactive stresses between the offset protrusions of the first and second patterned rolls. The resulting three-dimensional product is shown in fig. 5, which illustrates a pattern of protrusions 20 and connecting elements 30 arranged in a first sub-pattern region 60 and a second sub-pattern region 61, each region having two rows of protrusions 20 and connecting elements 30, which provide a visually dynamic image of this particular embodiment of the present invention.

The meshing of the nested rolls may be set to about 0.065 ". The paper may be fed through the nip at a speed of about 120 fpm. The resulting paper will have a protrusion height greater than about 300 μm, the protrusions having a diameter P in the range of about 1000 μm to about 2500 μm. The lengths A and B of the connecting elements may range from about 1500 μm to about 4500 μm. The depth a and b to which the connecting elements are recessed from the raised protrusion areas may be in the range of about 300 μm to about 1400 μm.

Embodiment 2

Another example of a through-air dried, differential density structure as described in U.S. patent 4,528,239 may be formed by the following method. The TAD carrier fabric of example 1 was replaced by one carrier fabric consisting of 225 biaxial alternating deflection tubes per 2.54cm (inch) and having a resin height of about 0.03cm (0.012 "). The paper is also subjected to the embossing process of embodiment 1 to form the three-dimensional structures of the present invention having a protrusion height of greater than about 300 μm. The resulting paper will have a protrusion height greater than about 300 μm, the protrusions having a diameter P in the range of about 1000 μm to about 2500 μm. The lengths A and B of the connecting elements may range from about 1500 μm to about 4500 μm. The depth a and b to which the connecting elements are recessed from the raised protrusion areas may be in the range of about 300 μm to about 1400 μm.

Embodiment 3

An alternative embodiment of the present fibrous structure is a paper structure having a wet microcontraction greater than about 5% in combination with any known through-air drying process. Wet microcontraction is described in U.S. Pat. No. 4,440,597. An example of embodiment 3 can be made as follows. The increase in wire speed compared to a TAD carrier fabric results in a 10% reduction in wet fibre web. The TAD carrier fabric of embodiment 1 is replaced by a carrier fabric having a 5-split weave with 36 machine direction filaments and 32 cross direction filaments per inch. The net crepe reduction was 20%. The paper was also subjected to the embossing process of example 1 and the resulting paper had a protrusion height of greater than 650 μm. The resulting paper will have a protrusion height greater than about 300 μm, the protrusions having a diameter P in the range of about 1000 μm to about 2500 μm. The lengths A and B of the connecting elements may range from about 1500 μm to about 4500 μm. The depth a and b to which the connecting elements are recessed from the raised protrusion areas may be in the range of about 300 μm to about 1400 μm.

Embodiment 4

Another embodiment of a fibrous structure suitable for use in the present invention is a through-air dried paper structure having longitudinal impression knuckles, as described in U.S. patent 5,672,248. A commercially available single ply substrate made in accordance with U.S. patent 5,672,248 having a basis weight of about 11.3kg/278m2(25lb/3000 square feet), a wet burst strength of about 340g, a thickness of about 0.081cm (.032 "), and a cross-directional peak elongation of about 12%, sold under the trade name Scott and manufactured by kimberly clark Corporation, which will be subjected to the embossing process of embodiment 1. The resulting paper has a protrusion height of greater than 300 μm. The resulting paper will have a protrusion height greater than about 300 μm, the protrusions having a diameter P in the range of about 1000 μm to about 2500 μm. The lengths A and B of the connecting elements may range from about 1500 μm to about 4500 μm. The depth a and b to which the connecting elements are recessed from the raised protrusion areas may be in the range of about 300 μm to about 1400 μm.

Test method

Primos height test method

The height was measured using a GFM Primos Optical Profiler apparatus commercially available from GFMesstechnik GmbH of D14513 Teltow/Berlin, Warthestra β e 21, Germany. The GFM Primos Optical Profiler apparatus includes a compact Optical measurement sensor based on digital micromirror projection, consisting of the following main components: a) a DMD projector with 1024 x 768 aligned digitally controlled micromirrors, b) a CCD camera with high resolution (1300 x 1000 pixels), c) projection optics suitable for measuring areas of at least 27 x 22mm, and d) recording optics suitable for measuring areas of at least 27 x 22 mm; a short tripod based on small hard stone slabs; a cold light source; a computer for measuring, controlling and evaluating; the software ODSCAD 4.0 English version of the measurement, control and evaluation value; and adjustment probes for lateral (x-y) and vertical (z) calibration.

The GFM Primos Optical Profiler system measures the surface height of a sample using digital micromirror pattern projection technology. The results of the analysis are a plot of surface height (z) versus xy displacement. The system has a field of view of 27 x 22mm with a resolution of 21 microns. The height resolution should be set between 0.10 and 1.00 microns. The height range is 64,000 times the resolution.

To measure a fibrous structure sample, the following steps should be followed:

1. the cold light source is turned on. The settings on the cold light source should be 4 and C, which should give a reading of 3000K on the display.

2. The computer, monitor and printer are turned on and the ODSCAD 4.0 Primos software is turned on.

3. Select the "Start Measurement" icon from the Primos taskbar and then click on the "Live Pic" button.

4. A30 mm by 30mm sample of the fibrous structure product conditioned for two hours at a temperature of about 23 deg.C + -1 deg.C (73 deg.F + -2 deg.F) and a relative humidity of 50% 2% is placed under the projection head and the distance is adjusted to obtain the best focus.

5. Repeatedly clicking the "Pattern" button projects one of several focusing patterns to help achieve the best focus (the software reticle should be aligned with the projected reticle when the best focus is achieved). The projection head is positioned normal to the sample surface.

6. Adjusting the image brightness by changing the aperture on the lens and/or changing the camera "gain" setting on the screen through a hole in the side of the projector head. The "gain" is not set higher than 7 to control the amount of electronic noise. When the lighting is optimal, the red circle labeled "i.o." at the bottom of the screen will turn green.

7. The "Technical Surface/Rough" (Technical Surface/roughness) measurement type was chosen.

8. Click the "Measure" button. This will freeze the live image on the screen while the image will be captured and digitized. It is important to keep the sample stationary during this time to avoid blurring of the captured image. The image will be captured in approximately 20 seconds.

9. If the image is satisfactory, the image is saved to the computer file with the extension ". omc". This will also save the camera image file ". kam".

10. To transfer the data into the analysis portion of the software, the clipboard/man icon is clicked.

11. Now, click on the icon "Draw Cutting Lines" (Draw cut line). The active line is determined to be line 1. Move the cross hair to the lowest point on the left side of the computer screen image and click the mouse. Then move the cross hair to the lowest point on the right side of the computer screen image on the current line and click the mouse. Now click "Align" (Align) through the icon of the marker point. Now click the mouse on the lowest point on the line and then click the mouse on the highest point on the line. Click on the "Vertical" distance icon. The distance measurements are recorded. The active wire is now raised to the next wire and the previous steps are repeated, which is done until all wires (six (6) wires in total) have been measured. All recorded data are averaged and, if the unit is not micron, converted to micron (μm). The number is the embossing height. This procedure was repeated for another image in the fibrous structure product sample and the average of the embossing heights was taken.

All documents cited in the detailed description of the invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims (10)

1. A three-dimensional product comprising a structure having a first surface and a z-direction perpendicular to the first surface, the structure further comprising a base, a plurality of raised protrusion areas raised at least about 300 μ ι η, preferably at least about 650 μ ι η, beyond the base of the structure, and a plurality of connecting elements, each connecting element terminating in a raised protrusion and each connecting element raised in the z-direction beyond the base of the structure and at least partially recessed from the raised protrusion in the z-direction, wherein the connecting elements connect two of the raised protrusion areas; the plurality of raised protrusion areas and the plurality of connecting elements together form a pattern comprising at least a first sub-pattern area and a second sub-pattern area, preferably comprising more than two sub-pattern areas; wherein the first sub-pattern region comprises a first set of parallel rows of raised protrusion regions and connecting elements and a second set of parallel rows of raised protrusion and connecting elements that are not parallel to the first set of parallel rows, and the first sub-pattern region is structurally distinguishable from the second sub-pattern region.

2. The three-dimensional product of claim 1, wherein the first sub-pattern region comprises a first set of parallel rows of raised protrusion regions and connecting elements and a second set of parallel rows of raised protrusion and connecting elements that are not parallel to the first set of parallel rows, and the second sub-pattern region does not comprise any protrusion or connecting elements.

3. The three-dimensional product according to any of claims 1 or 2, wherein the first sub-pattern region comprises at least two sets of parallel rows of alternating protrusions and connecting elements and the second sub-pattern region comprises at least two sets of parallel rows of alternating protrusions and connecting elements, wherein the first and second sub-pattern regions are structurally distinguishable due to rotation, reduction or enlargement, or alteration of the pattern in the first sub-pattern region.

4. The three-dimensional product according to any of the preceding claims, wherein the first sub-pattern region comprises at least two sets of parallel rows of alternating protrusions and connecting elements and the second sub-pattern region comprises at least two sets of parallel rows of alternating protrusions and connecting elements, the parallel rows being rotated such that they are not parallel to the parallel rows of the first sub-pattern region.

5. The three-dimensional product of any of the preceding claims, wherein the pattern of sub-pattern regions comprises a repeating pattern of the sub-pattern regions.

6. The three-dimensional product according to any of the preceding claims, wherein the structure is formed from a material selected from the group consisting of uncoated or coated paper, polymeric or plastic films, cloths or fabrics, woven materials, nonwoven materials, laminates, metal foils, and combinations thereof, preferably the structure comprises a tissue-towel paper product.

7. The three-dimensional product according to any of the preceding claims, wherein said pattern of protrusions and connecting elements is formed by an embossing process, preferably by a deep nested embossing process.

8. A tissue-towel paper product comprising an embossed pattern which conveys more than one communicated image by rotating the viewing angle of the product or changing the illumination angle or intensity.

9. A tissue-towel paper product according to claim 8 which when viewed from a first viewing angle conveys a first communicated image and when viewed from a second viewing angle conveys a second communicated image resulting from a change in angle selected from the group consisting of: a rotation around the z-direction of the product, a change in the viewing angle between the z-coordinate and the viewing line, a change in the surface topography or a combination of these changes.

10. A tissue-towel paper product according to claim 9 wherein the product is in the form of a roll and when viewed from a viewing angle in the z-coordinate above the roll, the product conveys a first communicated image and when viewed from the same viewing angle after rotating the roll on its axis, the product conveys a second image.