Multi-layer embossed tissue paper product

Description

1 / 53 Multi-layer embossed tissue paper product

[001] This request is split from BR 11 2021 016438 3, dated March 6, 2019. FUNDAMENTALS

[002] In the manufacture of paper products, particularly tissue paper products, it is generally desirable to provide an aesthetically pleasing end product with the highest possible volume without compromising other product attributes, including softness, flexibility, absorbency, hand feel, and durability. However, most papermaking machines operating today utilize a process known as wet pressing. In wet pressing, a large amount of water is removed from the newly formed paper web by mechanically pressing the water out of the web at a pressure narrowing. A disadvantage of the pressing step is that it densifies the web, thus decreasing the volume and absorbency of the sheet.A problem encountered in the past with the first wet pressing of the web and / or after dry stamping is the difficulty in obtaining a tissue paper base sheet with good functionality, such as absorbency and softness, combined with a pleasing appearance. This wet pressing step, although an effective means of dehydration, compresses the web and causes a sharp reduction in web thickness, thus reducing volume. Furthermore, the use of embossing to apply signature designs to a dry web generally results in a paper product that is resistant to the hand feel, stiffer at the edges, and with lower absorbency. Petition 870250028746, dated 09 / 04 / 2025, page 11 / 83 2 / 53

[003] Alternatives to wet compression, such as air drying, generally subject the web to less compression during manufacture. For example, air drying typically involves forming a wet web from a papermaking pulp in a forming medium such as a screen or forming screen. The wet web is then transferred to an air-permeable fabric by drying around an open drum and dries non-compressively by passing hot air through the web while in intimate contact with the fabric. Air drying is a preferred method of drying a web because it avoids the compressive force of the dewatering step used in the conventional wet press method for tissue paper manufacturing. The resulting web can optionally be transferred to a Yankee dryer for creping. Such processes are typically referred to as air-dried (CTAD).Since the web is substantially dry when transferred to the Yankee dryer, the process does not thicken the sheet as much as the wet pressing process; however, embossing may still be necessary to provide a tissue paper product with designs and sheet volume preferred by the consumer. As with wet-pressed webs, embossing has the disadvantage of a product that is rough to the touch, stiffer at the edges, and with lower absorbency.

[004] An alternative to CTAD is the non-creped air-drying (UCTAD) process described in Patents 5,591,309 and 5,593,545. By eliminating the creping step, the resulting blanket has a relatively high volume, good compressibility, and high resilience, with the resulting benefits of greater absorption and better fiber utilization. Although the improved volume and resilience of the blanket may Petition 870250028746, dated 09 / 04 / 2025, page 12 / 83 3 / 53 While these features are desirable from the consumer's perspective, they make the blanket difficult to engrave. Often, the patterns conveyed by the embossing of a UCTAD blanket are poorly defined and fade over time as the resilient blanket relaxes.

[005] Because it is poorly suited for embossing, tissue paper manufacturers wishing to create UCTAD webs with design motifs have often resorted to using patterned air-drying fabrics. For example, U.S. Patent Nos. 6,749,719 and 7,624,765 disclose fabrics useful in forming tissue paper webs with design elements using the UCTAD process. While these fabrics can provide webs with design elements, they also impart an overall textured background pattern to the web. Thus, it can be difficult to discern the design elements. In addition, adding design elements to air-drying fabrics reduces air permeability, which in turn reduces manufacturing efficiency.

[006] Consequently, there remains a need in the art to impart molded, air-dried webs with an embossing design without negatively affecting the physical properties of the web or the efficiency with which the webs are manufactured. There also remains a need for an embossing method, particularly a method for embossing high-volume, molded, air-dried tissue paper webs that provides an aesthetically appealing multi-layered product and improved sheet volume. SUMMARY

[007] It has now been discovered that multi-layered, embossed, air-dried products can be improved by providing the two outermost layers with different patterns. Petition 870250028746, dated 09 / 04 / 2025, page 13 / 83 4 / 53 stamping processes that result in layers with different tensile strengths. For example, in certain cases, the first layer may be stamped with the first pattern comprising line stamping elements and the second layer may be stamped with a second stamping pattern comprising dot stamping elements. The resulting multi-layered tissue paper products have layers of different tensile strength, such as a first layer having a geometric mean tensile strength (GMT) greater than 500 g / 3, such as from about 500 to about 600 g / 3, and a second layer having a GMT less than 500 g / 3, such as from about 300 to about 500 g / 3. Ideally, the difference in GMT between the first and second layers should be at least about 20 percent, as well as between about 20 and about 50 percent.

[008] Consequently, in one embodiment the present invention provides a multi-layer embossed tissue paper product comprising: a first embossed tissue paper fold; a second embossed tissue paper fold, wherein the first embossed tissue paper fold has a geometric mean tensile strength that is at least about 20 percent greater than the geometric mean tensile strength (GMT) of the second embossed tissue paper fold. For example, the first layer may have a GMT of about 550 to about 600 g / 3 and the bottom layer may have a GMT of about 300 to about 400 g / 3.

[009] In another embodiment, the present invention provides a multi-layer embossed tissue paper product with a first and a second outer surface comprising: a first fold of air-dried tissue paper embossed with Petition 870250028746, dated 09 / 04 / 2025, p. 14 / 83 5 / 53 a molded topographic pattern and a first embossed pattern; a second fold of air-dried embossed tissue paper with a molded topographic pattern and a second embossed pattern, wherein the first outer surface of the tissue paper product has a TS7 value that is at least about 10 percent greater than the TS7 value of the second outer surface of the tissue paper product. For example, the first layer may have a TS7 greater than about 11.5, such as from about 11.5 to about 13.0, and the second layer may have a TS7 less than about 11, such as from about 10 to about 11.

[0010] In yet another embodiment, the present invention provides a multi-layer embossed tissue paper product having a first and a second outer surface comprising: a first layer of dry embossed tissue paper having a molded topographic pattern, a first embossed pattern consisting essentially of line elements and a GMT of about 500 to about 600 g / 3; a second layer of embossed tissue paper having a molded topographic pattern, a second embossed pattern consisting essentially of embossed dot elements and a GMT that is at least about 20 percent less than the GMT of the first layer of embossed tissue paper; and wherein the first outer surface of the tissue paper product has a TS7 value that is at least about 10 percent greater than the TS7 value of the second outer surface of the tissue paper product.

[0011] In still other embodiments, the present invention provides a method for making an embossed tissue paper product comprising the steps of: (a) depositing an aqueous suspension of papermaking fibers Petition 870250028746, dated 09 / 04 / 2025, page 15 / 83 6 / 53 (provision) in an endless forming fabric to form a wet blanket; (b) dehydrate at least partially the wet blanket; (c) transfer the partially dehydrated blanket to an air-drying fabric that has a pattern on it; (d) mold the blanket in the patterned air-drying fabric to give a first molded topographic pattern to the blanket; (e) air-dry the patterned blanket; (f) stamp the patterned blanket to give a first stamped pattern to the blanket and provide a first layer of stamped tissue paper; (g) stamp the patterned blanket to give a second stamped pattern to the blanket and provide a second layer of stamped tissue paper;(e) and (h) folding the first and second embossed layers together to produce a multi-layered tissue paper product, wherein the first embossed tissue paper layer has a geometric mean tensile strength that is at least about 20 percent greater than the geometric mean tensile strength (GMT) of the second embossed tissue paper layer.

[0012] In certain embodiments, the first molded topographic pattern, the first embossed pattern, and the second embossed pattern are different but visually related to each other. For example, the first molded topographic pattern may comprise a plurality of wave-shaped line elements oriented substantially in the machine direction (MD), the second stamping pattern may comprise a plurality of wave-type curvilinear elements oriented in the direction substantially transverse to the machine consisting of embossed line elements, and the third embossed pattern may comprise a plurality of wave-shaped curvilinear elements consisting of dot embossed elements. Surprisingly, providing the Petition 870250028746, dated 09 / 04 / 2025, page 16 / 83 7 / 53 second layer with wave-shaped curvilinear elements consisting of dot relief elements, particularly a pattern with a pattern density of about 5 to about 15 reliefs per square centimeter, provides the desired level of tensile degradation and also increases the volume of the tissue paper product.

[0013] Consequently, in another embodiment, the present invention provides a multi-layer embossed tissue paper product comprising a first layer of tissue paper having a first side and an opposite second side, the first side having a molded topographic pattern and a first embossed pattern comprising a plurality of elements arranged thereon, the first layer having a first GMT of 500 g / 3 or greater, such as from 500 to about 600 g / 3; a second layer of fabric having a first side and an opposite second side, the first side having a molded topographic pattern and a second embossed pattern comprising a plurality of embossed dot elements arranged thereon, the second layer having a second GMT of less than 500 g / 3, such as from about 300 to less than 500 g / 3. DESCRIPTION OF THE FIGURES

[0014] FIG. 1 is a top plan view of a molded tissue paper product useful in the present invention; FIG. 2 is a top plan view of a stamping pattern useful in the present invention; FIG. 3 is a top plan view of a tissue paper product according to an embodiment of the present invention; FIG. 4 is a top plan view of a tissue paper product according to another embodiment of the present invention; Petition 870250028746, dated 09 / 04 / 2025, page 17 / 83 8 / 53 FIG. 5 is a top plan view of a stamping pattern useful in the present invention; FIG. 6 is a top plan view of another stamping pattern useful in the present invention; FIG. 7 is a top plan view of yet another stamping pattern useful in the present invention; FIG. 8 is a schematic view of a stamping process useful in the preparation of tissue paper products according to an embodiment of the present invention; Figures 9 to 12 are top views of stamping patterns used to prepare various samples of tissue paper products described herein; FIG. 13 is a graph comparing the difference in individual tissue paper layer strength, measured as geometric mean tensile strength (GMT, with units of g / 3), for commercial and inventive multi-layer tissue paper products; FIG. 14 is a graph comparing the difference in individual tissue paper layer softness, measured as TS7, for commercial and inventive multi-layer tissue paper products; and FIG. 15 illustrates the preparation of a sample for testing using a fabric softness analyzer, as described in the Test Methods section below. DEFINITIONS

[0015] As used in this document, the term base sheet refers to the tissue paper web formed by any of the papermaking processes described in this document, but which has not undergone further processing to convert the sheet into a finished product, such as stamping, calendering, perforating, folding, folding or rolling. Petition 870250028746, dated 09 / 04 / 2025, page 18 / 83 9 / 53 in individual laminated products.

[0016] As used herein, the term “tissue paper product” refers to products made from tissue paper sheets and includes toilet paper, facial tissues, paper towels, industrial cleaners, cleaning cloths for the food industry, napkins, medical liners and other similar products. Tissue paper products may comprise one, two, three or more layers.

[0017] As used in this document, the term fold refers to a discrete sheet of tissue paper used to form a tissue paper product. Individual folds can be arranged by juxtaposing them to each other.

[0018] As used here, the term Standard of Background generally refers to a predominant overall pattern laid across the surface of a fabric product, such as a molded topographic pattern or an embossed pattern.

[0019] As used in this document, the term Plan of Surface generally refers to the plane formed by the highest points of an object, such as the topmost surface of an embossing roll or the topmost surface of a tissue paper product. The surface plane can be determined by imaging a cross-section of the object, such as a tissue paper product, and drawing a line tangent to the highest point of its top surface, where the line is generally parallel to the x-axis of the object's surface and does not intersect any part of the object.

[0020] As used herein, the term Pattern generally refers to the arrangement of one or more design elements. Within a given pattern, the design elements may Petition 870250028746, dated 09 / 04 / 2025, page 19 / 83 10 / 53 being the same or different, additionally the design elements may be of the same relative size or may be of different sizes. For example, with reference to FIG. 3, the tissue paper product 150 comprises two patterns – a molded topographic pattern 155 comprising a plurality of raised edges 151 and valleys 153 between them, forming parallel and equally spaced sinusoidal wave elements, and an embossed pattern 160 comprising a plurality of curvilinear embossed line elements 162. In certain embodiments, a single design element may be repeated in a pattern, but the size of the design element may be different from one design element to the next within the pattern.

[0021] As used herein, the term motif generally refers to the recurrence of one or more design elements within a pattern. The recurrence of the design element may not necessarily occur within a given sheet of paper product; for example, in certain embodiments, the design element may be a continuous design element that extends across two adjacent sheets separated from each other by a line of perforations. Motifs are generally non-random repeating units that form a pattern.

[0022] As used in this document, the term Linear Element refers to an element in the form of a line, which may be continuous, discrete, interrupted, or a partial line in relation to a tissue paper product in which it is present. The linear element may have any suitable shape, such as straight, wavy, curved, and mixtures thereof. In one example, the linear element may comprise a Petition 870250028746, dated 09 / 04 / 2025, page 20 / 83 11 / 53 plurality of discrete elements, such as dots, dashes or broken lines, for example, that are arranged in relation to each other to form a linear element with a substantially connected visual appearance.

[0023] As used in this document, the term Curvilinear Element refers to any curved linear element having at least one inflection point. A curvilinear element need not be a line element, but may comprise discrete points, strokes, or line segments that are substantially visually connected. For example, with reference to FIG. 5, the stamping pattern 140 comprises a plurality of curvilinear elements 142a, 142b formed from a plurality of point stamping elements 144a, 144b. Although formed from point embossing elements 144a, 144b, the curvilinear element 142a has a substantially connected visual appearance.

[0024] Curvilinear elements can be used to form one or more design elements according to the present invention. In certain embodiments, a design element can be formed from a single curvilinear element or from a plurality of similarly shaped and spaced curvilinear elements.

[0025] As used in this document, the term Continuous when referring to an element arranged on the surface of a tissue paper product, such as a linear element, a design element, or a pattern, means that the element extends along one dimension of the surface of the tissue paper product. A non-limiting example of a continuous pattern is illustrated in FIG. 1. Pattern 102 of FIG. 1 Petition 870250028746, dated 09 / 04 / 2025, p. 21 / 83 12 / 53 comprises a plurality of sinusoidal waveform line elements 106a-106c extending from a first edge 101 to a second edge 103 of product 100.

[0026] As used herein, the term Discrete when referring to an element arranged on the surface of a tissue paper product, such as a line embossing element, a dot embossing element, a molded element or a pattern, means that the element is visually disconnected from the other elements. For example, FIG. 1 illustrates three discrete line elements 106a-106c.

[0027] As used in this document, the term Embossing Pattern generally refers to the arrangement of one or more design elements on the surface of a tissue paper product, resulting from the tissue paper product being conveyed through a narrowing comprising an embossed roll. The design elements may be discrete, semi-continuous or continuous and may comprise a line embossing element, a dot embossing element or combinations thereof. The embossing pattern generally comprises a portion of the tissue paper product that lies below the top surface plane of the tissue paper product.

[0028] As used herein, the term dot stamping generally refers to a stamping having a ratio of stamping length, measured along the longer dimension of the stamping, to stamping width, measured along the shorter dimension of the stamping, of approximately 1:1. Non-limiting examples of dot embossing are embossing that has the shape of circles, squares, rectangles, squares, or diamonds. A Petition 870250028746, dated 09 / 04 / 2025, p. 22 / 83 13 / 53 A plurality of spaced-point reliefs that are substantially connected visually can form a linear element, despite the reliefs being spaced from each other.

[0029] As used in this document, the term line embossing element generally refers to an engraving having a length-to-width ratio, measured along the longest dimension of the engraving, to the width-to-length ratio, measured along the shortest dimension of the engraving, greater than 1.

[0030] As used in this document, the term Relief Plane generally refers to the plane formed by the upper surface of the depressed portion of the tissue paper product that forms the relief. Generally, the plane of the embossing element lies below the plane of the tissue paper product surface. In certain embodiments, the tissue paper product of the present invention may have a single plane of the embossing element, while in other embodiments the structure may have multiple planes of the embossing element. The plane of the embossing element is generally determined by imaging a cross-section of the tissue paper product and drawing a line tangent to the uppermost surface of an embossing, where the line is generally parallel to the x-axis of the tissue paper product.

[0031] As used in this document, the terms Protrusion and Recording Element generally refer to any protrusion, bump, ridge, finger, head, step, surface, or similar, having a directional height z when measured from the axis of the roll, or some other common reference point. Generally, the height is Petition 870250028746, dated 09 / 04 / 2025, p. 23 / 83 14 / 53 measured from the base surface of the roll, which is understood to be the peripheral surface of the roll with the lowest radial height when measured from the roll axis, or some other common reference point.

[0032] As used in this document, the term Basis Weight (BW) generally refers to the dry weight of bone per unit area of ​​a tissue and is usually expressed as grams per square meter (g / m2). Basis weight is measured using the TAPPI T-220 test method. Although basis weight may vary, tissue paper products prepared according to the present invention generally have a basis weight greater than about 10 g / m2, such as from about 10 to about 80 g / m2 and more preferably from about 30 to about 60 g / m2.

[0033] As used in this document, the term Gauge is the representative thickness of a single sheet (gauge of tissue paper products comprising two or more layers is the thickness of a single sheet of tissue paper product comprising all layers) measured according to the TAPPI T402 test method using a ProGage 500 Thickness Tester (Thwing-Albert Instrument Company, West Berlin, NJ). The micrometer has an anvil diameter of 2.22 inches (56.4 millimeters) and an anvil pressure of 132 grams per square inch (per 6.45 square centimeters) (2.0 kPa). The gauge of a tissue paper product may vary depending on a variety of manufacturing processes and the number of layers in the product; however, tissue paper products prepared according to the present invention generally have a gauge greater than about 600 µm, more preferably greater than about 700 µm, and even more Petition 870250028746, dated 09 / 04 / 2025, page 24 / 83 15 / 53 preferably higher than about 8:00 pm, such as from about 6:00 to about 9:00 pm.

[0034] As used in this document, the term “sheet volume” refers to the quotient of the gauge (usually in units of µm) divided by the dry basis weight (usually in units of g / m2). The resulting sheet volume is expressed in cubic centimeters per gram (cm3 / g). Although the sheet volume may vary depending on any of a number of factors, tissue paper products prepared according to the present invention may have a sheet volume greater than about 15.0 cm3 / g, such as from about 15.0 to about 20.0 cm3 / g, such as from about 16.0 to about 18.0 cm3 / g.

[0035] As used in this document, the term geometric mean tensile strength (GMT) refers to the square root of the product of the tensile strength in the machine direction and the tensile strength in the transverse machine direction of the tissue paper product. Although the GMT may vary, tissue paper products prepared according to the present invention may have a GMT greater than about 700 g / 3, such as from about 700 to about 1,400 g / 3, such as from about 800 to about 1,200 g / 3.

[0036] As used herein, the term Stretch generally refers to the rate of corrected gap elongation of a sample at the point that generates its peak load divided by the corrected gap measurement length in any given orientation. Stretch is a result of MTS TestWorks™ throughout the process for determining tensile strength, as described in the Test Methods section of this document. Stretch is reported as a percentage and may be Petition 870250028746, dated 09 / 04 / 2025, p. 25 / 83 16 / 53 indicated by machine-directed stretch (MDS), cross-machine stretch (CDS), or as geometric mean stretch (GMS), which is the square root of the product of the machine-directed stretch and the cross-machine stretch. Although the extent of the tissue paper products prepared according to the present invention may vary, in certain embodiments the tissue paper products prepared as disclosed in this document have a GMS greater than about 8 percent, more preferably greater than about 10 percent and even more preferably greater than about 12 percent, such as from about 8 to about 14 percent, such as from about 10 to about 12 percent.

[0037] As used in this document, the terms TS7 and TS7 value refer to an output from an EMTEC Tissue Softness Analyzer (commercially available from Emtec Electronic GmbH, Leipzig, Germany), as described in the Test Methods section. The units of the TS7 value are dB V2 rms; however, TS7 values ​​are often mentioned in this document without reference to units. The TS7 value is the frequency peak that occurs around 6.5 kHz in the noise spectrum graph output of the EMTEC Tissue Softness Analyzer. This peak represents the softness of the sample. Generally, softer samples produce a lower TS7 peak.

[0038] As used in this document, the term average TS7 generally refers to the TS7 value for a first and second side of a tissue paper product. In certain embodiments, the invention provides a multi-layer embossed tissue paper product, such as a paper product. Petition 870250028746, dated 09 / 04 / 2025, p. 26 / 83 17 / 53 air-dried tissue, having an average TS7 of less than about 12.0 and more preferably less than about 11.0, such as from about 10.0 to about 12.0. The above average TS7 values ​​can be obtained in a GMT product of about 800 to about 1,200 g / 3, such as from about 800 to about 1,000 g / 3. DETAILED DESCRIPTION

[0039] The present inventors have now discovered that tissue paper products, particularly multi-layered air-dried tissue paper products having a three-dimensional surface topography, having improved softness and sheet volume, can be produced by embossing each of the layers. More particularly, the inventors have discovered that it may be useful to provide a tissue paper product with a first tissue paper layer with a molded topographic pattern and a first embossed pattern comprising a plurality of embossed elements arranged thereon and a second tissue layer with a molded topographic pattern layer and a second embossed pattern comprising a plurality of embossed dot elements arranged thereon.

[0040] Providing the first and second layers with different embossing patterns not only yields an aesthetically pleasing tissue paper product, but the resulting product can also have certain improved physical properties. For example, the tissue paper product can have layers of different strengths, such as a first layer that is stronger than the second layer. Therefore, in certain embodiments, the invention provides a tissue paper product with a first layer having medium tensile strength. Petition 870250028746, dated 09 / 04 / 2025, page 27 / 83 18 / 53 geometric (GMT) greater than 500 g / 3, such as from about 500 to about 600 g / 3 and a second layer having a GMT less than 500 g / 3, such as from about 300 to about 500 g / 3. Preferably, the difference in GMT between the first and second layers is at least about 10 percent, more preferably at least about 20 percent and even more preferably at least about 30 percent, such as from about 10 to about 50 percent and more preferably from about 20 to about 50 percent and even more preferably from about 30 to about 50 percent.

[0041] In other embodiments, the invention provides a tissue paper product with a first layer having a machine-directed tensile strength (MDT) greater than 700 g / 3, such as from 700 to about 900 g / 3 and a second layer having an MDT of about 600 g / 3 or less, such as from about 400 to about 600 g / 3. Preferably, the difference in MDT between the first and second layers is at least about 10 percent, more preferably at least about 20 percent and even more preferably at least about 30 percent, such as from about 10 to about 50 percent and more preferably from about 20 to about 50 percent and even more preferably from about 30 to about 50 percent.

[0042] The difference in tensile strength between the first and second layers can result in a product with different smoothness on each of its outer surfaces. For example, in certain embodiments, the multi-layered tissue paper product of the present invention has a stronger first layer with an outer surface having a Petition 870250028746, dated 09 / 04 / 2025, page 28 / 83 19 / 53 first softness value, usually measured as TS7, and a second, weaker layer having an outer surface having a second softness value that is lower than the first softness value. In one embodiment, the first outer surface of the tissue paper product has a TS7 value that is at least about 10 percent higher than the TS7 value of the second outer surface of the tissue paper product. For example, the first layer may have a TS7 higher than about 11.5, such as from about 11.5 to about 13.0, and the second layer may have a TS7 lower than about 11, such as from about 10 to about 11.

[0043] In still other embodiments, multilayer tissue paper products generally have improved sheet volume, such as a sheet volume greater than about 15 cubic centimeters per gram (cm3 / g), and improved softness, such as an average TS7 less than about 12.0 and more preferably less than about 11.0, such as from about 10.0 to about 12.0. The aforementioned average TS7 values ​​can be obtained at a geometric mean tensile strength (GMT) of the product of about 800 to about 1,200 g / 3, such as from about 800 to about 1,000 g / 3.

[0044] The tissue paper products of the invention differ from commercially available multi-layered tissue paper products, which generally have layers of similar tensile strength and softness. The table below compares several commercially available tissue paper products and several inventive tissue paper products in this respect. A comparison of inventive and commercially available tissue paper products is further illustrated in FIGS. 13 and 14. Petition 870250028746, dated 09 / 04 / 2025, p. 29 / 83 20 / 53 TABLE 1 Product GMT (g / 3) Top layer GMT (g / 3) Bottom layer GMT (g / 3) Difference from GMT (%) Top surface TS7 Bottom surface TS7 Difference from TS7 (%) Quilted Northern Mega Roll 924 405 451 -11 13.41 13.96 4 Charmin Soft Mega Roll 754 345 349 -1 9.14 9.72 6 Charmin Strong Mega Roll 1142 517 506 2 11.87 12.46 5 Inventive 874 566 378 33 11.91 10.55 11 Inventive 911 575 324 44 12.44 10.44 16

[0045] In certain preferred embodiments, improved products can be achieved by stamping the first and second layers with different stamping patterns, such as stamping patterns with different shapes, sizes, scales, or element densities. The use of two different stamping patterns can also provide the benefit of producing a product with different patterns that provide a distinct and attractive appearance to consumers.

[0046] Generally, the first and second stamping patterns are combined with a tissue paper product that has a molded pattern. The molded pattern, which may comprise a plurality of parallel and spaced linear elements, may form an overall background pattern upon which the pattern of Petition 870250028746, dated 09 / 04 / 2025, page 30 / 83 21 / 53 stamping can be applied. For example, the tissue paper product may comprise a first and a second layer, wherein each layer comprises a molded background pattern consisting essentially of a plurality of parallel and substantially machine-directed (MD) oriented, continuous, wave-like bumps spaced apart from each other by valleys. The first layer may further comprise a first embossed pattern consisting essentially of line elements, such as continuous curvilinear elements. The second layer may comprise a second embossed pattern consisting essentially of a plurality of dot embossed elements, which in certain cases may be arranged to form a curvilinear element.

[0047] Thus, in certain preferred embodiments, tissue paper products may be manufactured using a first and a second embossing roll having a first and a second embossing pattern that is different.For example, the first print pattern might comprise linear elements, which can be discrete or continuous, and the second print pattern might comprise non-linear elements. Although in certain cases the first and second print patterns may be different, they can be related to each other. For example, the patterns might comprise curvilinear elements that are visually related and provide the fabric product with an overall aesthetic that is desirable to a consumer.

[0048] In addition to forming, at least partially, the first and second stamping patterns from curvilinear elements, it may be advantageous to further relate the patterns by providing the elements with a scale. Petition 870250028746, dated 09 / 04 / 2025, page 31 / 83 22 / 53 similar. For example, the first engraving pattern may comprise a curvilinear line element with a first shape, such as a wave, with two inflection points defining a segment length of about 30 to about 60 mm, and the second engraving pattern may comprise a plurality of raised dot elements arranged to form a curvilinear element also having a wave-like shape with two inflection points and a segment length of about 30 to about 60 mm.

[0049] In still other cases, the first and second stamping patterns may also be related to a molded topographic pattern arranged in the tissue paper layer. For example, the molded topographic pattern may comprise a plurality of spaced parallel curvilinear elements, such as MD-oriented sinusoidal waves, and both the first and second embossing patterns may also comprise curvilinear elements, such as sinusoidal waves.

[0050] Patterns can also be visually related to each other, forming patterns with curvilinear elements having related weights or widths. For example, where the molded topographic pattern and early relief patterns are formed from curvilinear elements consisting of line elements, the patterns can be related to each other using similar line widths to form the curvilinear elements.

[0051] By providing patterns with similar shapes, scales, and line thicknesses, the patterns can appear complementary to each other and enhance the overall aesthetics of the tissue paper product, making it more visually appealing. Petition 870250028746, dated 09 / 04 / 2025, page 32 / 83 23 / 53 for consumers. Furthermore, by relating the patterns in terms of shape, scale, and line weight, the overall design connotations such as femininity, softness, and cleanliness are enhanced.

[0052] Those skilled in the art will appreciate that a wide variety of design elements can be used to create the various patterns, such as the molded topographic pattern, the first stamping pattern, and the second stamping pattern. For example, in certain embodiments, the patterns may consist essentially of curvilinear elements. In other embodiments, the patterns may comprise a combination of curvilinear and rectilinear or straight elements. In still other embodiments, the patterns may consist essentially of rectilinear or straight elements.

[0053] Several non-limiting examples of curvilinear elements are illustrated in the accompanying figures. For example, with reference to FIG. 1, the tissue paper product 100 having a machine direction (MD) and a cross-machine direction (CD) comprises a molded curvilinear pattern 102 disposed on its surface 105. The curvilinear pattern 102 comprises a plurality of continuous, wave-like line elements substantially oriented by MD 106a-106c. The wave-shaped topographic pattern repeatedly crosses the MD axis 108 to define an element angle (α), which in certain embodiments may be about 20 degrees or less, such as about 1 to about 20 degrees and more preferably about 5 to about 15 degrees and even more preferably about 8 to about 12 degrees.

[0054] With continuous reference to FIG. 1, the elements of Petition 870250028746, dated 09 / 04 / 2025, p. 33 / 83 24 / 53 line elements 106 are generally arranged parallel to each other so that no line element overlaps. In this way, the line elements are generally discrete. Furthermore, each of the line elements 106 has a width (W), which in a preferred embodiment is substantially constant between and among line elements. In addition, each of the line elements 106a-106c is spaced from each other by a distance (P). Each line element 106 can be shaped so that a portion of the element forms the uppermost surface 105, also referred to in this document as a shaped peak 107. Generally, the shaped peak 107 lies above the layer surface 109 between adjacent peaks. In certain cases, the surface between peaks 109 may be referred to here as a shaped valley.

[0055] With reference now to FIG. 2, another embodiment of a curvilinear pattern 130 is illustrated. The pattern 130, which is illustrated as being engraved on a surface 122 of the embossing roll 120, comprises a plurality of discrete curvilinear line elements 132a-132c. The wave-shaped curvilinear line elements 132a-132c are arranged so as to be visually connected and form a continuous pattern 130 extending from a first edge 135 to a second edge 137 of the embossing roll 120.

[0056] Two or more patterns, such as a molded pattern and an embossed pattern, can be combined into a single tissue paper product, such as the product illustrated in FIG. 3. The illustrated tissue paper product 150 comprises a tissue paper fold 152 with an outer surface 154 and two main dimensions – a machine direction (MD) and a cross-machine direction (CD). Product 150 includes a pattern Petition 870250028746, dated 09 / 04 / 2025, page 34 / 83 25 / 53 topographic molded 155 defined by high ridges 151 and valleys 153 between them. Product 150 further comprises a first embossed pattern 160 comprising motifs 164 having paired curvilinear line elements 162a, 162b. The curvilinear line elements 162a, 162b form a motif 164 which is repeated to form the first embossed pattern 160. The motifs 164 are arranged in a repeated manner so that the resulting pattern 160 extends continuously across the outer surface 154 of the first layer 152 from a first product edge 156 to a second product edge 157. In addition, the pattern 160 has a main orientation axis 167 which generally extends in the transverse direction of the machine and is oriented at an angle to the orientation axis of the molded pattern 169, which may be oriented along the machine direction.

[0057] Embossed elements are generally formed by stamping a layer of tissue paper using a stamping roll having a pattern corresponding to a first stamping pattern engraved on it. As such, the embossed element is generally a depression with a lower surface situated below the surface plane of the layer. The shape and depth of the embossing can be controlled by the shape and height of the protrusions on the engraved stamping roll that form the embossing. Furthermore, according to the present invention, the embossed elements generally overlap a background pattern, which is preferably formed by molding the layer before drying in the blanket manufacturing process. The molded topographic pattern generally has a three-dimensional shape, such as an upper surface plane and a lower surface plane. In certain cases, the upper surface plane may Petition 870250028746, dated 09 / 04 / 2025, page 35 / 83 26 / 53 correspond to shaped peaks and the lower surface plane may correspond to shaped valleys.

[0058] With continuous reference to FIG. 3, the product 150 further comprises a molded topographic pattern 155 defined by raised ridges 151 and valleys 153 between them. The molded topographic pattern 155 generally forms an overall background pattern and is overlaid by the first embossed pattern 160. The molded topographic pattern 155 generally has the form of a continuous sinusoidal wave with an orientation axis 169 that is substantially aligned with the machine direction. The ridges and valleys 151, 153 that form the molded pattern 155 are generally parallel to each other and uniformly spaced. Although the illustrated pattern consists of equally spaced elements, the invention is not so limited. In certain alternative embodiments, the spacing may vary between the pattern elements and, in certain cases, the spacing between two elements may vary as the element extends along a dimension of the product surface.

[0059] With reference now to FIG. 4, yet another embodiment of a product 150 prepared according to the present invention is illustrated. The product 150 comprises a first outer layer 152 having an upper surface 154. The product 150 further comprises a molded topographic pattern 155 defined by high ridges 151 and valleys 153 between them and a first embossed pattern 160. The first embossed pattern 160 comprises discrete curvilinear line embossed elements 162a-162d that form a motif 164 and are repeated to form an embossed pattern 160. In the illustrated embodiment, the embossed line elements 162a-162d are similarly dimensioned in terms of width, length and Petition 870250028746, dated 09 / 04 / 2025, page 36 / 83 27 / 53 depth, however, the invention is not so limited. In certain embodiments, the depth of the embossing is greater than about 0.5 mm, such as from about 0.5 to about 2.0 mm. The depth is generally measured as the distance between the lower surface of the embossing and the upper surface plane of the tissue paper product.

[0060] As further illustrated in FIG. 4, the outer surface 152 comprises raised areas 170 and non-raised areas 172, also referred to in this document as land areas. In the illustrated embodiment, the land areas 172 are surrounded by raised portions 170 comprising raised line elements 162. The raised line elements 162, which are discrete line elements, appear to be continuous and together form a continuous raised pattern 160 extending from a first edge 156 to a second edge 157 of the tissue paper product 150. In certain embodiments, the raised area may be at least about 5 percent and more preferably at least about 7.5 percent and even more preferably at least about 10 percent, such as from about 5 to about 30 percent and more preferably from about 10 to about 25 percent, of the surface area of ​​the first layer.Furthermore, the depth of the embossing can be at least about 0.5 mm, and more preferably at least about 0.75 mm, as well as from about 0.5 to about 1.5 mm.

[0061] With reference now to FIG. 5, an embodiment of a stamping pattern 140 is illustrated which can be incorporated into the second layer of a tissue paper product according to the present invention. As shown, the stamping pattern 140 comprises a plurality of elements of Petition 870250028746, dated 09 / 04 / 2025, p. 37 / 83 28 / 53 stamping of dots 144a, 144b which are arranged to form pattern 140. In the illustrated embodiment, the dot relief elements 144a, 144b are arranged to form spaced, continuous, curvilinear elements 142a, 142b having a wave-like shape which is substantially oriented in the machine direction (MD).

[0062] In those embodiments where one or more of the patterns consist of a waveform, such as a sinusoidal wave, the amplitude may vary from about 10 to about 40 mm and even more preferably from about 18 to about 22 mm, and the wavelength may vary from about 50 to about 200 mm and even more preferably from about 80 to about 120 mm. For example, in a particular embodiment, the second layer may comprise a molded background pattern and a raised dot pattern wherein both patterns comprise a plurality of sinusoidal wave elements with an amplitude ranging from about 10 to about 40 mm and a wavelength ranging from 80 to about 120 mm. The amplitude and wavelength of the patterns may be the same for molded and raised patterns or may be different. Furthermore, the molded and raised patterns may be continuous or may be discrete.

[0063] Another embodiment of a dot relief pattern 140 is shown in FIG. 6. Like the pattern in FIG. 5, the dot relief pattern in FIG. 6 is wave-shaped and comprises a plurality of dot relief elements 144a, 144b arranged to form spaced, continuous, curvilinear elements 142a, 142b. The wave-shaped pattern 140 in FIG. 6, however, has a shorter period than the wave-shaped pattern in FIG. 10. Therefore, in certain Petition 870250028746, dated 09 / 04 / 2025, p. 38 / 83 29 / 53 modalities, the second layer may include a pattern of raised dots comprising a plurality of curvilinear wave-shaped elements with a wavelength of about 50 to about 200 mm, as well as about 80 to about 120 mm.

[0064] Yet another embodiment of a dot embossing pattern 140 is shown in FIG. 7. Pattern 140 comprises a plurality of dot embossing elements 144a, 144b arranged to form spaced curvilinear elements 142a, 142b. The pattern may comprise from about 10 to about 15 dot embossing elements 144a, 144b per square centimeter and result in a tissue paper product with dot embossing elements covering from about 8 to about 12 percent of the surface area of ​​the tissue paper product.

[0065] In addition to curvilinear design elements, particularly wave-shaped elements such as sinusoidal waves, other embossed dot patterns arranged in the second layer may include other shapes such as zigzag or helical designs. In still other embodiments, the dot embossing pattern may not be an overall pattern arranged substantially uniformly across the surface of the second tissue paper layer. Instead, the dot embossing pattern may include additional designs and patterns incorporated into the background pattern.

[0066] In the embodiment illustrated in FIGS. 5 to 7, the point relief elements are present at a density of about 10 to about 25 reliefs per square centimeter. In other embodiments, the density of point relief elements present in the second layer may vary from Petition 870250028746, dated 09 / 04 / 2025, page 39 / 83 30 / 53 approximately 5 to approximately 25 reliefs per square centimeter, such as approximately 7.5 to approximately 20, such as approximately 10 to approximately 15 reliefs per square centimeter. The spacing of point relief elements within a given linear element can be varied, as well as the spacing of linear elements relative to each other, to provide the desired density. For example, in the embodiments illustrated in FIGS. 5 and 6, within each linear element, the point relief elements are spaced approximately 0.16 cm from the center of one relief to the center of an adjacent relief. The distance between adjacent linear elements is approximately 0.24 cm from the center of one element to the center of an adjacent element. In this embodiment, the reliefs themselves have a longer dimension of approximately 0.14 cm.

[0067] In certain embodiments, both the spacing between dot relief elements within a given linear element and the dot reliefs in adjacent elements can be substantially uniform for a given pattern. In other embodiments, the spacing can be varied between intra-element dot relief elements and inter-element dot relief elements. Consequently, in certain cases, the density of the dot relief element can be substantially uniform along a given pattern and in other cases the density can vary within a given pattern to have areas of high and low density.

[0068] The various dot relief patterns illustrated are just a few examples of patterns that can be used according to the present invention. In certain embodiments, the dot reliefs are arranged in a pattern such that by Petition 870250028746, dated 09 / 04 / 2025, page 40 / 83 31 / 53 less about 2 percent, and more preferably at least about 5 percent, of the surface area of ​​the tissue paper is covered by dot reliefs. In other embodiments, the percentage of the tissue paper surface area covered by dot reliefs may vary from about to about 15 percent, as well as from about 5 to about percent.

[0069] In other cases, the size of the pattern created by the dot reliefs can be increased or decreased. For example, the density of the dot relief elements within a pattern can vary from about 7.5 to about 20, particularly from about 7.5 to about 15 reliefs per square centimeter and still achieve a soft, high-volume tissue paper product according to the present invention. Furthermore, the dot relief elements themselves can assume various shapes, such as, for example, circles, ovals, diamonds, hexagons, triangles, or any other suitable geometric formation. In particularly preferred embodiments, the dot relief elements are circular and have a diameter of about 0.075 to about 0.25 cm.

[0070] The multilayer tissue paper products of the present invention can be manufactured using the apparatus shown in FIG. 8. To produce a first embossed layer, a first tissue paper layer 201, which will form the top layer of the finished tissue paper product, is unwound from a first master roll 202 and conveyed by a series of tension rolls 220 towards a first embossed layer 210 located between a first embossed roll 212 and a first roll of Petition 870250028746, dated 09 / 04 / 2025, page 41 / 83 32 / 53 printing 211. The engraved recording roller 212 rotates counterclockwise, while the printing roller 211 rotates clockwise.

[0071] The engraved stamping roll 212 is generally a rigid, non-deformable roll, such as a steel roll, and comprises a plurality of protrusions 216, also referred to herein as engraving elements, extending radially from a first peripheral surface 219. The protrusions are arranged so as to form at least one first stamping pattern. An example of a stamping pattern formed on the outer surface of the first engraved stamping roll is shown in FIG. 2. The protrusions have a radial height generally measured from the first peripheral surface of the roll, which is understood to be the circumferential surface of the roll with the smallest radial height when measured from the axis of the roll, or some other common reference point. In certain embodiments, the radial height of the protrusions may be about 1.30 mm or more, such as from about 1.30 to about 1.50 mm, and more preferably from about 1.35 to about 1.45 mm.

[0072] The protrusions of the first recorded roll may comprise a first pattern consisting of linear elements and, more preferably, continuous line elements, wherein the linear elements are spaced from each other to form areas of terrain between them. The areas of terrain may be continuous or discontinuous within a given dimension of the recorded roll, depending on the arrangement of the linear elements forming the first pattern. The pattern may be continuous along at least one dimension of the roll. Petition 870250028746, dated 09 / 04 / 2025, p. 42 / 83 33 / 53 recorded and, even more preferably, is a regular and repetitive pattern arranged along at least one dimension of the recorded roll.

[0073] The spacing and arrangement of the elements forming the first pattern may vary depending on the desired properties and appearance of the tissue paper product. The element shape may also be varied to provide the desired properties and appearance of the tissue paper product. For example, in one embodiment, the linear elements forming the first pattern are curvilinear and more preferably sinusoidal and are arranged substantially parallel to each other so that none of the elements intersect. In other embodiments, the linear elements may occur as wave-like patterns that are arranged in phase with each other so that the spacing between adjacent elements is substantially constant. In other embodiments, the linear elements may form a wave pattern in which adjacent elements are offset from each other.

[0074] Regardless of the particular shape of the first element and the resulting motif and pattern, or whether adjacent elements within a pattern are in or out of phase with each other, it is generally preferred that there be some portion of the roll surface along which adjacent elements within a pattern are separated from each other. In this way, the roll comprises areas of ground between adjacent elements. In a particularly preferred embodiment, the first pattern comprises a plurality of spaced linear elements, where the pattern is arranged continuously across both x and y dimensions of the Petition 870250028746, dated 09 / 04 / 2025, p. 43 / 83 34 / 53 The surface of the engraved roll and adjacent linear elements are spaced from each other in dimension y by at least about 1.0 cm, such as from about 1.0 to about 5.0 cm and more preferably from about 2.0 to about 4.0 cm.

[0075] Referring again to FIG. 8, the first embossed roller 212 is driven against the first printing roller 211, which preferably has a substantially smooth deformable outer surface. In certain cases, the printing roller may be a roller with a covering made of natural or synthetic rubber, for example, polybutadiene or ethylene and propylene copolymers or the like. In a particularly preferred embodiment, the outer surface of the printing roller has a hardness greater than about 40 Shore (A), such as from about 40 to about 100 Shore (A) and more preferably from about 40 to about 80 Shore (A). By providing a printing roller with the above hardness levels, the embossed roller designs are not pressed into the printing roller as deeply as in conventional apparatus.

[0076] The first printing roller 211 and the first embossed stamping roller 212 are driven together to form a first stamping narrowing 210 through which the first fabric layer 201 passes to impose a first stamping pattern on it. Generally, a force or pressure is applied to one or both rollers, so that the rollers are driven against each other, causing the printing roller to deform over the protrusions, so that when the layer is pressed over the protrusions and on the support areas (i.e., areas of the outer surface of the roller around the protrusions) Petition 870250028746, dated 09 / 04 / 2025, page 44 / 83 35 / 53 results in embossing. As the first layer of embossed tissue paper 205 emerges from the first embossing narrowing 210, it comprises a plurality of embosses 230 having distal ends 232.

[0077] To form a two-layer tissue paper product, a second main roll 202 is unwound and the second tissue paper layer 204 is carried around a tension roll 220 and is then passed to a second embossing taper 215 formed between a second printing roll 217 and a second embossed printing roll 213. The second printing roll generally has a smooth outer surface, which may be deformable. In certain cases, the second printing roll has an outer covering comprising a natural or synthetic rubber and may have a hardness greater than about 40 Shore (A), such as from about 40 to about 100 Shore (A). The second embossed embossing roll 213 generally comprises a plurality of protrusions 222 extending from its peripheral surface 221. The protrusions are generally in the form of dot elements and form a second embossed pattern.In certain embodiments, the protrusions arranged on the second embossed roll may have a height of at least about 0.4 mm, as well as from about 0.4 to about 2.0 mm.

[0078] As the second layer 204 passes through the second embossing narrowing 215, it is conveyed with a plurality of point embossing elements 231, which can be arranged to form a pattern. The second embossed layer 224 is then conveyed and placed face-to-face with the first embossed layer 205 using a matching roller 240, as will be described in more detail below. Petition 870250028746, dated 09 / 04 / 2025, p. 45 / 83 36 / 53 Although in certain cases the second engraved recording roller 213 and the printing roller 217 may be arranged relatively close to the first pair of rollers 211, 212 and the matching roller. 240, this is not necessary because the present method does not depend on the registration of the first and second stamping patterns with each other. In this way, the present method differs from the so-called nested embossing method, as described in U.S. Publication No. 20120156447, where the stamping elements of the first stamping roll and the stamping elements of the second stamping roll are arranged in such a way that the stamping elements of the first stamped layer and the stamped elements of the second stamping screen fit into each other in a manner similar to a gear system.

[0079] After the second embossed layer 224 leaves the second embossing narrowing 215, it is brought into relation with the first embossed layer 205. The two embossed layers 205, 224 are conveyed through a third narrowing 242 formed between the first embossed embossing roll 212 and a matching roll 240, which may be a steel roll with a substantially smooth outer surface. The first and second embossed layers 205, 224 are joined as they pass through the third narrowing 242 to form a multi-layered tissue paper product 280.

[0080] With continuous reference to FIG. 8, in certain embodiments, after exiting the first stamping narrowing 210, the first stamped layer 205 encounters an adhesive unit 250, which comprises an adhesive 251 disposed in a reservoir and an applicator roller 252. The adhesive 251 is transferred to the applicator roller 252 and Petition 870250028746, dated 09 / 04 / 2025, p. 46 / 83 37 / 53 applied to the distal ends 232 of the embossings 230 that are formed on the outer surface of the first embossed tissue layer 205 by virtue of contact with the first protrusions 216. The first embossed tissue paper layer 205 with the applied adhesive 251 then advances further to the third constriction 242 between the first embossed roll 212 and the matching roll 240. At this point, the second embossed layer 224 is attached to the first embossed layer 205 and then conveyed through the third constriction 242 to form a two-layer tissue paper product laminated with adhesive 280 which is subsequently wound onto a roll (not shown).

[0081] The resulting two-layer tissue paper product 280 comprises first and second embossed layers 205, 224, with the first embossed layer 205 forming the uppermost surface of the tissue paper product 280 and the second layer 224 forming the lowermost surface. In certain embodiments, the first embossed layer may comprise a first embossed pattern consisting essentially of a plurality of continuous curvilinear line element embosses, and the second layer may comprise a plurality of dot embossed elements arranged thereon in a pattern consisting essentially of curvilinear elements. Furthermore, although not illustrated in FIG. 8, each of the first and second tissue paper layers comprises a molded topographic pattern, which is generally transmitted to the layers before embossing.

[0082] In certain embodiments, to improve processability and one or more physical properties, one or more of the fibrous layers may be subjected to pre Petition 870250028746, dated 09 / 04 / 2025, p. 47 / 83 38 / 53 Conditioning to impart moisture and / or heat to tissue paper layers before entering a stamping narrowing. For example, pre-conditioning mechanisms can be positioned upstream of the narrowing located between the embossed roll and the printing function to introduce moisture and / or heat into the first tissue paper layer before stamping. The methods and arrangements for applying moisture and heat (e.g., steam) to tissue paper webs are known to those skilled in the art and can be employed and are within the scope of the present invention. As an example, steam can be applied to one or both sides of a web before embossing.

[0083] The tissue paper sheets useful in forming the multilayer tissue paper products of the present invention can be formed using any of several well-known manufacturing processes. For example, in certain embodiments, the tissue paper products can be produced by an air-drying (TAD) manufacturing process, an advanced tissue paper molding system (ATMOS) manufacturing process, a structured tissue paper technology (STT) manufacturing process, or belt creping. In particularly preferred embodiments, the tissue paper product is manufactured by a creped air-drying (CTAD) process or a non-creped air-drying (UCTAD) process.

[0084] Tissue paper weaves produced by early processes may impart an initial pattern through wet molding. For example, one or more design elements may be formed by wet molding the weave during manufacturing using a patterned paper production fabric, Petition 870250028746, dated 09 / 04 / 2025, page 48 / 83 39 / 53 such as an air-drying fabric with patterns that imparts the pattern onto the tissue paper weave as it dries. The dried web, which retains the molded pattern, can then be further converted, such as by embossing, to give a second pattern to the web.

[0085] In one embodiment, the tissue paper webs useful in the present invention are formed by the UCTAD process of: (a) depositing an aqueous suspension of papermaking fibers (pulp) onto an endless forming fabric to form a wet web; (b) at least partially dehydrating the wet web; (c) transferring the partially dehydrated web to an air-drying fabric that has a pattern on it; (d) molding the web onto the drying fabric using patterned air to provide a first pattern on the web; (e) air-drying the web; and (f) embossing the web to impart a second pattern on the web.

[0086] Multilayer tissue paper products produced according to the present invention not only have first and second patterns that may be aesthetically pleasing to a consumer, they may also have favorable physical properties, such as sufficient strength to withstand use while being soft and having a good feel to the touch. Consequently, in one embodiment, the present invention provides a multilayer embossed tissue paper product comprising: a first layer of tissue paper having a first side and an opposite second side, the first side having a molded topographic pattern and a first embossed pattern comprising a plurality of elements arranged thereon; a second layer of tissue paper having a first side and a second side Petition 870250028746, dated 09 / 04 / 2025, page 49 / 83 40 / 53 opposite side, the first side having a molded topographic pattern and a second embossed pattern comprising a plurality of dot relief elements arranged thereon, wherein the tissue paper product has a basis weight of about 10 to about 100 g / m2, and more preferably of about 15 to about 60 g / m2 and a sheet volume greater than about 15.0 cm3 / g and more preferably greater than about 16.0 cm3 / g, and even more preferably greater than about 17.0 cm3 / g, such as from about 15.0 to about 20.0 cm3 / g.

[0087] In addition to having the previous basis weights and sheet volumes, the multilayer tissue paper products prepared according to the present invention may have a geometric mean tensile strength (GMT) greater than about 700 g / 3, such as from about 700 to about 1,400 g / 3, and more preferably from about 800 to about 1,200 g / 3 and even more preferably from about 800 to about 1,000 g / 3. At these tensile strengths, the tissue paper sheets and products have relatively low average TS7 values, such as less than about 12.0 and more preferably less than about 11.0, such as from about 10.0 to about 12.0.

[0088] In a particularly preferred embodiment of the present invention, a multi-layer embossed tissue paper product comprising: a first layer of tissue paper having a first side and an opposite second side, the first side having a molded topographic pattern and a first embossed pattern comprising a plurality of elements arranged thereon; a second layer of tissue paper having a first side and an opposite second side, Petition 870250028746, dated 09 / 04 / 2025, page 50 / 83 41 / 53 the first side having a molded topographic pattern and a second embossed pattern comprising a plurality of raised dot elements arranged thereon, wherein the tissue paper product has a basis weight of about 45 g / m2 or greater, a GMT of about 700 to about 1,000 g / 3, a TS7 average less than about 12.0 and a leaf volume greater than about 15.0 cm3 / g. TESTING METHODS Sheet Volume

[0089] The sheet mass is calculated as the quotient of the dry sheet gauge (pm) divided by the basis weight in dry weight (g / m2). The dry sheet gauge is the measurement of the thickness of a single sheet of tissue paper (including all folds), measured according to the TAPPI T402 test method, using a ProGage 500 Thickness Tester (ThwingAlbert Instrument Company, West Berlin, NJ). The micrometer has an anvil diameter of 2.22 inches (56.4 millimeters) and an anvil pressure of 132 grams per square inch (per 6.45 square centimeters) (2.0 kPa). Traction

[0090] Tensile tests were performed according to the TAPPI test method T-576 Tensile properties of tissue paper and paper towel products (with a constant rate of elongation) where the test is performed on a tensile testing machine maintaining a constant rate of elongation and the width of each specimen tested is 3 inches. More specifically, samples for dry tensile strength testing were prepared by cutting a strip 3 ± 0.05 inch (76.2 ± 1.3 mm) wide in the machine direction (MD) or in the cross-machine direction. Petition 870250028746, dated 09 / 04 / 2025, page 51 / 83 42 / 53 (CD) using a JDC precision sample cutter (ThwingAlbert Instrument Company, Philadelphia, PA, Model No. JDC 310, Serial Node 37333) or equivalent. The instrument used to measure tensile strength was a Sintech 11S, Serial No. 6233 from MTS Systems. The data acquisition software was MTS TestWorks® for Windows Ver. 3.10 (MTS Systems Corp., Research Triangle Park, NC). The load cell was selected from a maximum of 50 Newton or 100 Newton, depending on the strength of the sample being tested, so that most peak load values ​​fall between 10 and 90 percent of the full scale value of the load cell. The gauge length between the grips was 4 ± 0.04 inches (101.6 ± 1 mm) for face tissue paper and 2 ± 0.02 inches (50.8 ± 0.5 mm) for bath tissue paper. The head speed was 10 ± 0.4 inches / min (254 ± 1 mm / min), and the tear sensitivity was set at 65%.The sample was placed in the instrument's grips, centered both vertically and horizontally. The test was then started and ended when the specimen broke. The peak load was recorded as either the sample's "MD tensile strength" or "CD tensile strength," depending on the direction of the sample being tested. The geometric mean tensile strength (GMT) was calculated and is expressed in grams-force per 3 inches (7.6 cm) of sample width. The absorbed tensile energy (TEA) and slope are also calculated by the tensile tester. TEA is reported in units of gm*cm / cm². Slope is recorded in units of kg. Both TEA and slope are directionally dependent, and therefore the MD and CD directions are measured independently. The geometric mean TEA and the geometric mean slope are defined as the square root. Petition 870250028746, dated 09 / 04 / 2025, pp. 52 / 83 43 / 53 square of the product of the representative MD and CD values ​​for a given property.

[0091] The tensile strength of the product and related tensile properties were tested as multi-layer products, and the results represent the tensile strength of the total product. For example, a two-layer product was tested as a two-layer product and recorded as such. Five representative samples were tested for each multi-layer product, and the arithmetic mean of all individual sample tests was recorded as the appropriate tensile property of the sample.

[0092] The tensile strength and related tensile properties of individual layers of a multi-layered product were tested as individual single layers. Before testing each individual layer, care was taken to separate each layer from a multi-layered product to ensure that the layer was not damaged. Layers with tears or defects were discarded. Five representative samples were tested for each multi-layered product, with each sheet being tested individually, and the arithmetic mean of all individual sample tests was recorded as the appropriate tensile property of the given sheet. Softness of Tissue Paper

[0093] The softness of the tissue paper was measured using an EMTEC Tissue Paper Softness Analyzer (TSA) (Emtec Electronic GmbH, Leipzig, Germany). The TSA consists of a rotor with vertical blades that rotate over the test piece applying a defined contact pressure. The contact between the Petition 870250028746, dated 09 / 04 / 2025, pages 53 / 83 44 / 53 vertical blades and the test piece create vibrations, which are detected by a vibration sensor. Then, the sensor transmits a signal to a PC for processing and display. The signal is displayed as a frequency spectrum. For measuring TS7 values, the blades are pressed against the sample with a load of 100 mN and the rotation speed of the blades is two revolutions per second.

[0094] Frequency analysis in the range of approximately 200 to 1000 Hz represents the smoothness or texture of the test piece surface. The peak in the frequency range between 200 and 1000 Hz is referred to here as the TS750 value and is expressed as dB V2rms. A high peak amplitude correlates to a rougher surface.

[0095] An additional peak in the frequency range between 6 and 7 kHz represents the softness of the test piece. The peak in the frequency range between 6 and 7 kHz is referred to here as the TS7 value and is expressed as dB V2rms. The smaller the amplitude of the peak that occurs between 6 and 7 kHz, the softer the test piece will be.

[0096] In addition to TS750 and TS7, the analyzer reports a stiffness parameter (D) with units of mm / N. The stiffness parameter (D) is the deformation of the sample under a defined load.

[0097] Test samples were prepared by cutting a circular sample with a diameter of 112.8 mm. All samples were left to equilibrate under standard TAPPI temperature and humidity conditions for at least 24 hours before completing the TSA test. The softness of the outermost surface of each layer is tested separately. As illustrated in FIG. 14, a multi-layered product 300 having first and second outer surfaces 301, 303 is Petition 870250028746, dated 09 / 04 / 2025, page 54 / 83 45 / 53 separated into individual layers 302, 304, taking care not to damage the individual layers. Each layer 302, 304 is tested separately by placing an individual layer 302 or 304 in the TSA. The outer surface 301 or 303 of layer 302 or 304 is facing upwards in the TSA and is the surface contacted by the test apparatus 310 during the analysis.

[0098] The sample is clamped and measurements are initiated via PC. The PC records, processes, and stores all data according to the standard TSA protocol. The reported values ​​are the average of five repetitions, each with a new sample. EXAMPLES

[0099] The base sheets were made using an air-dry papermaking process commonly referred to as non-creped air-dry (UCTAD) and generally described in U.S. Patent No. 5,607,551, the contents of which are incorporated herein in a manner consistent with the present disclosure. Base sheets were produced with a target dry basis weight of approximately 26 grams per square meter (g / m2). The base sheets were then converted by calendering, stamping, folding, and winding to produce embossed two-ply tissue paper products.

[00100] In all cases, the base sheets were produced from a supply comprising northern hardwood kraft and eucalyptus kraft using a layered headbox, fed by three feed tanks, forming the webs with three layers (two outer layers and one middle layer). The two outer layers comprised eucalyptus kraft pulp (each layer comprising 30 percent by weight of the total weight of the web) and Petition 870250028746, dated 09 / 04 / 2025, page 55 / 83 46 / 53 The middle layer comprised northern softwood kraft pulp (comprising 30 percent by weight of the total weight of the mat). The middle layer contained temporary moisture resistance, Fennobond 3000 (commercially available in Kemira, Atlanta, GA), which was added at 2 kg per metric ton of material supplied. In certain cases, the softwood supply was refined to control resistance.

[00101] The tissue paper web was formed on a Voith Fabrics TissueForm V forming fabric, vacuum dehydrated to about 25 percent consistency, and then subjected to rapid transfer when transferred to the transfer fabric. The transfer fabric was the fabric described as Fred in U.S. Patent No. 7,611,607 (commercially available from Voith Fabrics, Appleton, WI). The web was then transferred to an air-drying fabric comprising a printed silicone pattern disposed on the contact side of the sheet. The silicone formed a wavy pattern on the contact side of the tissue sheet. The pattern had a height of about 0.6 mm, a wavelength of about 100 mm, and an amplitude of about 10 mm. The elements within the pattern were spaced from each other about 3.08 mm (center-to-center spacing).The transfer to the airflow drying screen was done using vacuum levels greater than 10 inches of mercury in the transfer. The blanket was then dried to approximately 98% solids before winding.

[00102] The base sheet was calendered using two conventional polyurethane / steel calenders. The first calender comprised a 40 P&J polyurethane roll on the air side of the sheet and a standard steel roll on the fabric side with a Petition 870250028746, dated 09 / 04 / 2025, p. 56 / 83 47 / 53 load of 75 pli. The second calendar comprised a 15 P&J polyurethane roller on the air side of the sheet and a standard steel roller on the fabric side with a load of 50 pli.

[00103] The calendered base sheet was then converted into two-layer laminated tissue paper products, substantially as illustrated in FIG. 1, by embossing the first and second layers separately and laminating the embossed layers to form a two-layer tissue paper product. The first layer was embossed using an embossing roll engraved with a pattern substantially similar to that illustrated in FIG. 2. The second layer was embossed using several different embossed rolls to evaluate their effect on the properties of the resulting tissue paper product. The properties of the embossed rolls used to emboss the second layer are summarized in Table 2 below. TABLE 2 Sample Stamping Pattern Figure Element Density (# / cm2) Surface Area (%) Element Pattern Orientation Pattern Axis 1 - - - - - 2 FIG. 9 14.1 10.7 - - 3 FIG. 10 14.1 10.7 Sinusoidal Wave CD 4 FIG. 11 7.3 5.5 Sinusoidal Wave MD 5 FIG. 12 10.5 7.9 Sinusoidal Wave CD

[00104] The two-layer tissue paper product was subjected to physical tests, the results of which are shown in Petition 870250028746, dated 09 / 04 / 2025, page 57 / 83 48 / 53 Table 3, below. TABLE 3 Sample Grammage (g / m2) Caliper (pm) Sheet volume (cm3 / g) GMT of the base sheet (g / 3) GMT Finished Product (g / 3”) Delta GMT (%) CD TEA (gm*cm / cm2) GM of stretch (%) 1 45.4 655 14.4 1374 1048 24% 8.39 12.9 2 45.1 663 14.7 1348 955 29% 7.62 11.2 3 45.1 701 15.5 1358 920 32% 7.82 10.3 4 45.1 721 16.0 1341 911 32% 7.20 10.6 5 44.6 693 15.5 1374 874 36% 6.93 10.4

[00105] Embossing the second layer increased tensile degradation, particularly when the second layer was embossed with a sinusoidal wave pattern. Embossing the layers also had the effect of giving each layer different tensile and softness properties. For example, as illustrated in Tables 4 and 5 below, the first fold was generally at least about 10 percent stronger than the second layer, while the second layer was generally softer than the first layer. TABLE 4 Sample First fold GMT (g / 3”) First fold MDT (g / 3”) First fold CD TEA (gm² / cm²) Second fold GMT (g / 3) Second fold MDT (g / 3) First fold CD TEA (gm² / cm²) Difference from GMT (%) 1 516 769 2.42 459 693 2.11 11 2 534 811 2.52 360 529 1.80 33 3 516 800 2.26 361 525 1.77 30 Petition 870250028746, dated 09 / 04 / 2025, pp. 58 / 83 49 / 53 4,575,870 2.53 324,500 1.42 44 5,566,870 2.35 378,500 1.89 33 TABLE 5 Sample Top Surface TS7 Top Surface TS750 Bottom Surface TS7 Bottom Surface TS750 Difference from TS7 (%) 1 10.88 72.25 11.07 68.60 2 2 11.62 65.83 10.50 66.62 10 3 11.88 69.84 10.93 70.00 8 4 12.44 66.22 10.44 64.14 16 5 12.44 66.22 10.44 64.14 11

[00106] Embossing the second layer with a patterned relief, particularly a wavy embossing pattern, was also particularly effective in increasing the sheet volume of the finished product, as illustrated in Table 6 below. Generally, supplying the second layer with a wave-type embossing pattern increased the sheet volume by about 8 to about 11 percent compared to a similar product comprising a non-embossed second layer. The increase in volume was also observed compared to embossing the second layer with a general background pattern. TABLE 6 Sample Grammage (g / m2) Caliper Gauge (pm) Sheet Volume (cm3 / g) Volume Delta (%) 2 45.1 663 14.7 2% 3 45.1 701 15.5 8% Petition 870250028746, dated 09 / 04 / 2025, p. 59 / 83 50 / 53 4 45.1 721 16.0 11% 5 44.6 693 15.5 8% MODALITIES

[00107] First embodiment: A multi-layer embossed tissue paper product comprising: a first layer of embossed tissue paper; a second layer of embossed tissue paper, wherein the first layer of embossed tissue paper has a geometric mean tensile strength that is at least about 20 percent greater than the geometric mean tensile strength (GMT) of the second layer of embossed tissue paper.

[00108] Second embodiment: The product of the first embodiment, wherein the first layer of embossed tissue paper comprises a molded topographic pattern and a first embossed pattern and wherein both patterns comprise a plurality of line elements.

[00109] Third modality: The product of the first or second modalities, in which the first and second layers comprise a relief pattern comprising a plurality of linear wave-shaped elements.

[00110] Fourth modality: The product of any of the first to third modalities, in which the molded topographic pattern, the first relief pattern and the second relief pattern are different.

[00111] Fifth modality: The product of any of the first to fourth modalities, where the product has a GMT of approximately 700 to approximately 1,200 g / 3.

[00112] Sixth type: The product of any of the first to fifth types, wherein the first layer of embossed tissue paper has a GMT greater than about 500 and the Petition 870250028746, dated 09 / 04 / 2025, pp. 60 / 83 51 / 53 second layer embossed tissue paper has a GMT lower than about 500.

[00113] Seventh embodiment: The product of any of the first to sixth embodiments, wherein the first layer of embossed tissue paper has an MD tensile strength greater than about 750 g / 3 and the second layer of embossed tissue paper has an MD tensile strength less than about 550 g / 3.

[00114] Eighth type: The product of any of the types from the first to the seventh having a basis weight of about 20 to about 60 grams per square meter (g / m2) and a volume greater than about 15 cubic centimeters per gram (cm3 / g).

[00115] Ninth embodiment: The product of any of the first to eighth embodiments, wherein the first layer of embossed tissue paper has a CD TEA greater than about 2.0 gf*cm / cm2 and the second layer of embossed tissue paper has a CD TEA less than about 1.0 gf*cm / cm2.

[00116] Tenth embodiment: The product of any of the first to ninth embodiments, wherein the first layer of embossed tissue paper has a first embossed pattern consisting essentially of embossed line elements and the second layer of embossed tissue paper has a second embossed pattern consisting essentially of embossed dot elements.

[00117] Eleventh embodiment: The product of any of the embodiments from the first to the tenth, wherein the first and second layers of tissue paper each comprise a layer of air-dried tissue paper with a molded topographic pattern.

[00118] Twelfth type: The product of any Petition 870250028746, dated 09 / 04 / 2025, pp. 61 / 83 52 / 53 one of the embodiments from the first to the eleventh in which the first and second layers of tissue paper are air-dried tissue paper sheets and comprise a molded topographic pattern that is transmitted by molding the sheet to an air-drying fabric.

[00119] Thirteenth embodiment: The product of any of the embodiments from the first to the twelfth, in which the first and second layers of tissue paper are adhesively bonded to each other in a plurality of bonded regions.

[00120] Fourteenth modality: The product of any of the modalities from the first to the thirteenth, in which at least a portion of the connected regions is formed between the relief area of ​​the first layer and the relief area of ​​the second layer.

[00121] Fifteenth embodiment: The product of any of the embodiments from the first to the fourteenth wherein the first layer comprises a first stamping pattern that is substantially free of point stamping elements and covers from about 10 to about 30 percent of the surface area of ​​the first layer; and wherein the second layer comprises a second stamping pattern that is substantially free of linear stamping elements and covers from about 2 to about 15 percent, and more preferably from about 5 to about 10 percent, of the surface area of ​​the second layer.

[00122] Sixteenth embodiment: The product of any of the embodiments from the first to the fifteenth, in which the first outer surface of the tissue paper product has a TS7 value that is at least approximately 10 percent greater than Petition 870250028746, dated 09 / 04 / 2025, pp. 62 / 83 53 / 53 is the TS7 value of the second outer surface of the tissue paper product.

[00123] Seventeenth embodiment: The product of any of the embodiments from the first to the sixteenth, wherein the second outer surface of the tissue paper product has a TS7 value of about 9.0 to about 11.0.

[00124] Eighteenth embodiment: The product of any of the first to sixteenth embodiments, wherein the first embossing consists essentially of linear embossing elements and covers from about 10 to about 30 percent of the surface area of ​​the first layer; and wherein the second embossing pattern consists essentially of dot embossing elements having a form selected from the group consisting of circles, squares, rectangles, diamonds and combinations thereof and wherein the dot embossing elements cover from about 5 to about 10 percent of the second layer surface area. Petition 870250028746, dated 09 / 04 / 2025, pages 63 / 83

Claims

1 / 2 CLAIMS 1. Multi-layer embossed tissue paper product having a first and a second outer surface, characterized in that it comprises: a. a first layer of air-dried embossed tissue paper having a molded topographic pattern and a first embossed pattern; b. a second layer of air-dried embossed tissue paper with a molded topographic pattern and a second embossed pattern, wherein the first outer surface of the tissue paper product has a TS7 value that is at least about 10 percent higher than the TS7 value of the second outer surface of the tissue paper product.

2. Multilayer embossed tissue paper product according to claim 1, characterized in that the second outer surface of the tissue paper product has a TS7 value of about 9.0 to about 11.

0.

3. Multilayer embossed tissue paper product according to claim 1, characterized in that the tissue paper product has a GMT of about 700 to about 1,200 g / 3 (g / 7.62 cm).

4. Multilayer embossed tissue paper product according to claim 1, characterized in that the first layer of embossed tissue paper has a GMT greater than about 500 g / 3 (g / 7.62 cm) and the second layer of embossed tissue paper has a GMT less than about 500 g / 3 (g / 7.62 cm) and the difference in GMT between the two layers is at least about 20 percent.

5. Embossed multilayer tissue paper product according to claim 1, characterized in that it has a basis weight of about 20 to about 60 grams per square meter (g / m2) and a volume greater than about 15 cubic centimeters per gram (cm3 / g).

6. Multilayer embossed tissue paper product according to claim 1, characterized in that the first embossing pattern Petition 870260052214, dated 05 / 29 / 2026, page 12 / 13 2 / 2 consists essentially of line embossing elements and the second embossing pattern consists essentially of dot embossing elements.

7. Multilayer embossed tissue paper product according to claim 1, characterized in that the first layer of embossed tissue paper has a GMT of about 500 to about 600 g / 3 (g / 7.62 cm), the second layer of embossed tissue paper has a GMT that is at least about 20 percent lower than the GMT of the first layer of embossed tissue paper, the first embossed pattern essentially consists of embossed line elements and the second embossed pattern essentially consists of embossed dot elements.

8. Multilayer embossed tissue paper product according to claim 7, characterized in that the tissue paper product has a GMT of about 700 to about 1,200 g / 3 (g / 7.62 cm).

9. Multilayer embossed tissue paper product according to claim 7, characterized in that it has a basis weight of about 20 to about 60 grams per square meter (g / m2) and a volume greater than about 15 cubic centimeters per gram (cm3 / g).

10. Multi-layer embossed tissue paper product according to claim 7, characterized in that the second outer surface of the tissue paper product has a TS7 value of about 9.0 to about 11.

0. Petition 870260052214, dated 05 / 29 / 2026, p. 13 / 13

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