Tissue products and methods for manufacturing the same

Abstract

Various implementations include a tissue product that includes a through-air dried tissue ply including a three-dimensional topography. The three-dimensional topography defines a first design element and a second design element encompassed within and discontinuous from the first design element. Various other implementations include a through-air dried fabric having a three-dimensional topography disposed thereon that forms the three-dimensional topography of the tissue ply. Various other implementations include a method of forming the tissue ply using the through-air dried fabric.

Description

[0001] TISSUE PRODUCTS AND METHODS FOR MANUFACTURING THE SAME

[0002] CROSS REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 516,764, filed on July 31, 2023, the entire contents of which are incorporated herein by reference.

[0004] BACKGROUND

[0005] Tissue products, such as facial tissues, paper towels, bath tissues, napkins, and other similar products, are designed to include several important properties. For example, the products should have good sheet bulk, a soft feel, and should have sufficient strength and durability to withstand manufacturing and use. It is also desirable to include a differentiated product appearance. Further, to improve wiping utility, it may be desirable to provide the product with a degree of surface texture. Unfortunately, however, when steps are taken to increase one property of the product, other characteristics of the product are often adversely affected.

[0006] It is generally known that molding a partially dewatered cellulosic web on a topographical papermaking fabric will enhance the finished paper product’s physical properties, such as sheet bulk, stretch and softness, and aesthetics. Such molding can be applied by fabrics in a through-air dried process, such as the process disclosed in U.S. Patent No. 5,672,248, or in a wet-pressed tissue manufacturing process, such as that disclosed in U.S. Patent No. 4,637,859.

[0007] Exemplary papermaking fabrics are disclosed in U.S. Patent No. 6,998,024, which discloses woven papermaking fabrics with substantially continuous machine direction ridges whereby the ridges are made up of multiple warp filaments grouped together. Known woven papermaking fabrics have generally been limited to continuous topographies oriented substantially in the machine direction, with some small degree of variability.

[0008] SUMMARY

[0009] Various implementations relate to a tissue product, such as a rolled bath tissue product, that includes at least one through-air dried tissue ply having a first surface and including a three- dimensional topographical pattern disposed thereon, the three-dimensional topographical pattern comprising a first design element and a second design element encompassed within and discontinuous from the first design clement.

[0010] Various other implementations relate to a through-air drying fabric for forming a tissue product. The through-air drying fabric includes a web contacting surface and an additive manufactured, three-dimensional topographical pattern disposed on the web contacting surface, the topographical pattern comprising a first design element and a second design element encompassed within and discontinuous from the first design element.

[0011] Various other implementations relate to a method of forming a through-air dried tissue ply having a pattern disposed thereon, wherein the pattern comprises a first design element and a second design element and wherein the second design element is encompassed within and discontinuous from the first design element. The method includes providing a through-air drying fabric having a web contacting surface and comprising an additive manufactured, three- dimensional topographical pattern disposed on the web contacting surface. The three- dimensional topographical pattern defines a first shape and a second shape encompassed within and discontinuous from the first shape. The method further includes forming an aqueous suspension of fibers, depositing the aqueous suspension of fibers onto a forming fabric to form a wet web, dewatering the wet web, transferring the dewatered wet web onto the web contacting surface of the through-air drying fabric, and through-air drying the dewatered wet web to form the through-air dried tissue ply. The through-air dried tissue ply includes an imprinted three- dimensional topographical pattern imparted to the through-air dried tissue ply by the topographical pattern disposed on the web contacting surface of the through-air drying fabric. The three-dimensional topographical pattern defines a first design element corresponding to the first shape of the through-air drying fabric and a second design element corresponding to the second shape of the through-air drying fabric.

[0012] BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a schematic representation of a tissue web forming system, according to some implementations .

[0014] FIG. 2 is a schematic representation of an additive manufacturing system, according to some implementations. FIG. 3 is a top view of a through-air drying fabric produced using the additive manufacturing system of FIG. 2 and used within the tissue web forming system of FIG. 1, according to some implementations.

[0015] FIGS. 4A, 4B, and 4C are top views of tissue products formed using the through-air drying fabric of FIG. 3, according to some implementations.

[0016] FIG. 5 is a close-up view of a through-air drying fabric, according to another implementation.

[0017] FIG. 6 is a photograph of a bath tissue produced using the through-air drying fabric of FIG. 5, according to some implementations.

[0018] FIG. 7 is a microscopy scan output of a portion of the bath tissue of FIG. 6 taken using a Keyence microscope, according to some implementations.

[0019] FIG. 8 is a close-up view of a through-air drying fabric, according to another implementation .

[0020] FIG. 9 is a photograph of a bath tissue produced using the through-air drying fabric of FIG. 8, according to some implementations.

[0021] FIG. 10 is a microscopy scan output of a portion of the bath tissue of FIG. 9 taken using a Keyence microscope, according to some implementations.

[0022] FIG. 11 is a close-up view of a through-air drying fabric, according to another implementation.

[0023] FIG. 12 is a photograph of a bath tissue produced using the through-air drying fabric of FIG. 11, according to some implementations.

[0024] FIG. 13 is a microscopy scan output of a portion of the bath tissue of FIG. 12 taken using a Keyence microscope, according to some implementations.

[0025] DETAILED DESCRIPTION

[0026] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present articles, systems, and / or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific or exemplary aspects of articles, systems, and / or methods disclosed unless otherwise specified, as such can, of course, vary. Tt is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0027] The following description of the disclosure is provided as an enabling teaching of the disclosure in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the disclosure described herein while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those of ordinary skill in the pertinent art will recognize that many modifications and adaptations to the present disclosure are possible and may even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is again provided as illustrative of the principles of the present disclosure and not in limitation thereof.

[0028] Definitions

[0029] As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Thus, for example, reference to a “filament” includes aspects having two or more such filaments unless the context clearly indicates otherwise.

[0030] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers, or steps.

[0031] For the terms “for example,” “exemplary,” and “such as,” and grammatical equivalences thereof, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise.

[0032] As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0033] It will be understood that the terms “first,” “second,” etc., may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or a section. Thus, a first clement, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of exemplary aspects.

[0034] The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, fluidic, etc. For example, circuit A communicably “coupled” to circuit B may signify that the circuit A communicates directly with circuit B (i.e., no intermediary) or communicates indirectly with circuit B (e.g., through one or more intermediaries).

[0035] Ranges may be expressed herein as from one particular value to another particular value. When such a range is expressed, another aspect includes from the one particular value to the other particular value. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint. Similarly, the values listed include approximations of these values. In one non-limiting aspect the terms are defined to be within 10%. In another non-limiting aspect, the terms are defined to be within 5%. In still another non-limiting aspect, the terms are defined to be within 1%.

[0036] Throughout this disclosure, various aspects of the disclosure can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, a description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.

[0037] As used herein, a “wet strength agent” is any material that, when added to pulp fibers, can provide a resulting web or sheet with a wet geometric tensile strength to dry geometric tensile strength ratio in excess of 0.1.

[0038] As used herein, the term “transfer fabric” refers to a fabric that is positioned between a forming section and a drying section of a web manufacturing process.

[0039] As used herein, the term “papermaking fabric” means any woven fabric used for making a cellulosic web, such as a tissue sheet, either by a wet-laid process or an air-laid process. Specific papermaking fabrics within the scope of this disclosure include forming fabrics; transfer fabrics conveying a wet web from one papermaking step to another, such as described in U.S. Patent No. 5,672,248; as molding, shaping, or impression fabrics where the web is conformed to the structure through pressure assistance and conveyed to another process step, as described in U.S. Patent No. 6,287,426; as a structured fabric adjacent to a wet web in a nip as described in U.S. Patent No. 7,476,293; or as a through-air drying fabric as described in U.S. Patent Nos. 5,429,686, 6,808,599, and 6,039,838. The fabrics of the disclosure are also suitable for use as molding or air-laid forming fabrics used in the manufacture of non-woven, non-cellulosic webs such as baby wipes.

[0040] As used herein, the term “discrete” refers to a three-dimensional element formed in the tissue web, such as a design element or a pattern, that is visually unconnected from other three- dimensional elements formed in the tissue web. A non-limiting example of a discrete design element is illustrated in FIG. 3 where the pattern 112 includes a set of shapes 122 having discrete closed design elements 124.

[0041] As used herein, the term “continuous” when referring to a plurality of three-dimensional elements of a papermaking fabric, such as protuberances, shapes, or patterns, means that the elements extend throughout one dimension of the web-contacting surface of the papermaking fabric.

[0042] As used herein, the term “discontinuous” when referring to a plurality of three- dimensional elements of a papermaking fabric, such as protuberances, shapes, or patterns, means that the elements are not continuous and that they are not in contact or touching. As used herein, the term “encompassed” when referring to a plurality of three- dimensional elements of a papermaking fabric, such as protuberances, shapes, or patterns, means that the elements are fully surrounded and positioned within another element.

[0043] As used herein, the term “pattern” refers to any non-random repeating design, figure, or motif. Generally, the fabrics and tissue products described herein may comprise decorative patterns comprising a plurality of raised or depressed line elements and / or a plurality of recesses. However, it is not necessary that the line elements form recognizable shapes, and a repeating design of the line elements and / or recesses is considered to constitute a decorative pattern.

[0044] As used herein the term “Design Element” generally refers to a shape or combination of shapes that visually create a distinct component. A design element is a curvilinear design element where it is at least partially formed by a curvilinear line element. A design element may be continuous or discrete. It is not necessary that a design element form a recognizable shape. The design element may be textured having a z-directional elevation relative to the plane of the tissue product, such as protrusions or depressions formed by wet molding of the tissue web during manufacture.

[0045] As used herein the term “Closed Design Element” generally refers the appearance of a design element on a given sheet where the design element has no beginning or end within the given sheet. Examples of various closed design elements 136, 138 are illustrated in FIG. 4A. In each instance the closed design elements 136, 138 have no beginning or end within the given sheet 82.

[0046] As used herein, the term “tissue product” refers to products made from tissue webs and includes bath tissues, facial tissues, paper towels, industrial wipers, foodservice wipers, napkins, medical pads, medical gowns, and other similar products. Tissue products may comprise one, two, three or more plies.

[0047] As used herein, the terms “tissue web” and “tissue sheet” refer to a fibrous sheet material suitable for forming a tissue product.

[0048] As used herein, the term “layer” refers to a plurality of strata of fibers, chemical(s) applied to the fibers, and / or the like, within a ply.

[0049] The term “ply” refers to a discrete product element. Individual plies may be arranged in juxtaposition to each other. The term may refer to a plurality of web-like components such as in a multi-ply facial tissue, bath tissue, paper towel, wipe, or napkin. As used herein, the term “wet-out time” generally refers to the time required for a tissue sample to completely saturate with a liquid and is determined as described in the Test Methods section. While the wet-out time of tissue products prepared according to the present disclosure may vary, in certain instances the wet-out time may be 10 sec. or less, such as 8.0 sec. or less, such as 6.0 sec. or less, such as from 4.0 to 10 sec.

[0050] As used herein, the term “absorbent capacity” generally refers to the total amount of liquid a tissue product may retain and is determined as described in the Test Methods section. While the absorbent capacity of tissue products prepared according to the present disclosure may vary, in certain instances the absorbent capacity may be 4.0 g / g or greater, such as 6.0 g / g or greater, such as 8.0 g / g or greater, such as 10.0 g / g or greater, such as from 4.0 g / g to 12.0 g / g.

[0051] As used herein, the term “basis weight” generally refers to the bone-dry weight per unit area of a tissue and is generally expressed as grams per square meter (gsm). Basis weight is measured as described in the Test Methods section below. While the basis weight of tissue products prepared according to the present disclosure may vary, in certain instances, one or two ply rolled bath tissue products have a basis weight of 30.0 gsm or greater, such as 34.0 gsm or greater, such as 36.0 gsm or greater, such as 38.0 gsm or greater, such as 40.0 gsm or greater, such as 42.0 gsm or greater, such as 44.0 gsm or greater, such as from 30.0 to 60.0 gsm, such as from 40.0 to 50.0 gsm.

[0052] As used herein, the term “roll firmness” or simply “firmness” generally refers to Kershaw Firmness, which is measured using the Kershaw Test as described in detail in U.S. Pat. No. 6,077,590 and in the Test Methods section below. The testing apparatus is available from Kershaw Instrumentation, Inc. (Swedesboro, N.J.) and is known as a Model RDT-2002 Roll Density Tester.

[0053] As used herein, the term “Sheet Caliper” refers to the thickness of a single tissue product, web, sheet or ply, typically having units of microns (pm) and is measured as described in the Test Methods section below. ). Tissue products prepared according to the present disclosure may vary, however, in certain instances tissue products may have a sheet caliper of 400 pm or greater, such as 425 pm or greater, such as 450 pm or greater, such as 460 pm or greater, such as from 400 to 500 pm.

[0054] As used herein, the term “Stack Caliper” refers to the thickness of a stack of ten (10) tissue products, webs, sheets or plies, typically having units of microns (pm) and is measured as described in the Test Methods section below. Tissue products prepared according to the present disclosure may vary, however, in certain instances tissue products may have a sheet caliper of 4000 pm or greater, such as 4200 pm or greater, such as 4400 pm or greater, such as 4500 pm or greater, such as from 4000 to 5000 pm.

[0055] As used herein, the term “Sheet Bulk” refers to the quotient of the caliper (pm) divided by the bone dry basis weight (gsm). The resulting sheet bulk is expressed in cubic centimeters per gram (cc / g). Tissue products prepared according to the present disclosure may vary, however, in certain instances tissue products may have a sheet bulk of 8.0 cc / g or greater, such as 9.0 cc / g or greater, such as 10.0 cc / g or greater, such as 12.0 cc / g or greater, such as from 8.0 cc / g to 14.0 cc / g.

[0056] As used herein, the term “Slope” refers to the slope of the line resulting from plotting tensile versus stretch and is an output of the MTS TestWorks™ in the course of determining the tensile strength as described in the Test Methods section herein. Slope is reported in the units of grams (g) per unit of sample width (inches) and is measured as the gradient of the least-squares line fitted to the load-corrected strain points falling between a specimen-generated force of 70 to 157 grams (0.687 to 1.540 N) divided by the specimen width.

[0057] As used herein, the term “Geometric Mean Slope” (GM Slope) generally refers to the square root of the product of machine direction slope and cross-machine direction slope. While the GM Slope may vary amongst tissue products prepared according to the present disclosure, in certain implementations, tissue products may have a GM Slope less than 10.00 kg, more preferably less than 9.00 kg and still more preferably less than 8.00 g, such as from 6.00 to 10.0 g, such as from 6.00 to 8.00 kg.

[0058] As used herein, the term “Geometric Mean Tensile” (GMT) refers to the square root of the product of the machine direction tensile strength and the cross-machine direction tensile strength of the web. The GMT of tissue products prepared according to the present disclosure may vary, however, in certain instances the GMT may be 700 g / 3" or greater, such as 800 g / 3" or greater, such as 900 g / 3'' or greater, such as from 700 1,700 g / 3", such as from 800 to 1,600 g / 3", such as from 900 to 1,500 g / 3".

[0059] As used herein, the term “Stiffness Index” refers to the quotient of the geometric mean tensile slope, defined as the square root of the product of the MD and CD slopes (having units of kg), divided by the average geometric mean tensile strength (having units of grams per three inches) multiplied by 1000.

[0060] The properties of the tissue web or tissue product described herein refer to the properties of the finished tissue web or tissue product, unless otherwise noted.

[0061] Although the operations of exemplary aspects of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that disclosed aspects can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may, in some cases, be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular aspect are not limited to that aspect and may be applied to any aspect disclosed.

[0062] Moreover, for the sake of simplicity, the attached figures may not show the various ways (readily discernable, based on this disclosure, by one of ordinary skill in the art) in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses. Additionally, the description sometimes uses terms such as “produce” and “provide” to describe the disclosed method. These terms are high-level abstractions of the actual operations that can be performed. The actual operations that correspond to these terms can vary depending on the particular implementation and are, based on this disclosure, readily discernible by one of ordinary skill in the art.

[0063] Process of Producing Through-Air Dried Tissue Products

[0064] Non-limiting examples of processes for making fibrous structures include known wet-laid papermaking processes, for example, through-air-dried papermaking processes. Such processes include steps of preparing a fiber composition in the form of a suspension in a medium, either wet, more specifically aqueous medium, or dry, more specifically gaseous (e.g., with air as medium). The aqueous medium used for wet-laid processes is oftentimes referred to as a fiber slurry. The fibrous slurry is then used to deposit a plurality of fibers onto a forming wire, fabric, or belt such that an embryonic fibrous structure is formed, after which drying and / or bonding the 1'ibers together results in a tissue web. Further processing of the tissue web may be carried out such that a finished tissue product is formed.

[0065] Examples of papermaking processes and techniques useful in forming tissue webs and products according to the present disclosure include, for example, those disclosed in U.S. Patent Nos. 5,048,589, 5,399,412, 5, 129,988 and 5,494,554. In some implementations, the tissue web is formed by through-air drying and may be cither crcpcd or uncrcpcd.

[0066] The forming process of the present disclosure may be any conventional forming process known in the papermaking industry. Such formation processes include, but are not limited to, Fourdriniers, roof formers such as suction breast roll formers, and gap formers such as twin wire formers and crescent formers.

[0067] The drying process can include any non-compressive drying method which tends to preserve the bulk or thickness of the wet web including, without limitation, through-air drying, infra-red radiation, microwave drying, etc. Because of its commercial availability and practicality, through-air drying is well known and is one commonly used means for non- compressively drying the web for purposes of this disclosure. The web is dried to final dryness on the through-air drying fabric, without being pressed against the surface of a Yankee dryer, and without subsequent creping.

[0068] The tissue webs disclosed herein may be converted into single or multi-ply tissue products, and the webs may be converted into rolled or sheets of a folded tissue product. Rolled tissue products may comprise a plurality of connected, but perforated sheets that may be dispensed as adjacent sheets. In another example, the tissue products may be in the form of discrete sheets that are stacked within and dispensed from a container, such as a box.

[0069] Tissue webs disclosed herein may be homogeneous or may be layered. If layered, the tissue web may comprise two or more layers, such as two, three, or four layers. If desired, various chemical compositions may be applied to one or more layers of the multi-layered tissue web to further enhance softness and / or reduce the generation of lint or slough. For example, in some aspects, a wet strength agent can be utilized, to further increase the strength of the tissue product. Typically, these materials are termed either “permanent” wet strength agents or “temporary” wet strength agents. As is well known in the art, temporary and permanent wet strength agents may also sometimes function as dry strength agents to enhance the strength of the tissue product when dry.

[0070] A paper product base web can be formed by an uncreped through-air drying process. In some implementations, a twin wire former can be used to form the paper product base web. In some implementations, another former configuration can be used. As shown in FIG. 1, a tissue web forming system 50 includes papermaking headbox 54 that deposits a furnish of an aqueous suspension of papermaking fibers onto an outer forming fabric 58 and an inner forming fabric 62 to form a wet tissue web 66.

[0071] The wet tissue web 66 forms on the inner forming fabric 62 as the inner forming fabric 62 revolves a forming roll 70. The inner forming fabric 62 serves to support and carry the newly formed wet tissue web 66 downstream in the process as the wet tissue web 66 is partially dewatered to a consistency of 10 percent based on the dry weight of the fibers. Additional dewatering of the wet tissue web 66 may be carried out by known papermaking techniques, such as vacuum suction boxes, while the inner forming fabric 62 supports the wet tissue web 66. The wet tissue web 66 may be additionally dewatered to a consistency of at least 20 percent based on the dry weight of the fibers, including example values of 20 to 40 percent and 20 to 30 percent.

[0072] The inner forming fabric 62 can generally be made from any suitable porous material, such as metal wires or polymeric filaments. For example, some suitable fabrics can include, but are not limited to, Albany 84M and 94M, available from Albany International (Albany, N.Y.) Asten 856, 866, 867, 892, 934, 939, 959, or 937; Asten Synweve Design 274, all of which are available from Asten Forming Fabrics, Inc. (Appleton, Wis.); and Voith 2164 available from Voith Fabrics (Florence, MS). Forming fabrics or felts comprising nonwoven base layers may also be useful, including those of Scapa Corporation made with extruded polyurethane foam such as the Spectra Series.

[0073] The wet web 36 is then transferred from the inner forming fabric 62 to a transfer fabric 74. In some implementations, the wet tissue web 66 can have a consistency of 10 to 35 percent, including example values of 20 to 30 percent based on the dry weight of the fiber present within a set volume of water. Exemplary transfer fabrics are described in U.S. Patent No. 11,286,623.

[0074] Transfer to the transfer fabric 74 may be carried out with the assistance of positive and / or negative pressure. For example, in one aspect, a vacuum shoe 78 can apply negative pressure such that the inner forming fabric 62 and the transfer fabric 74 simultaneously converge and diverge at the leading edge of a vacuum slot. Typically, the vacuum shoe 78 supplies negative machine direction pressure at levels of 3 to 7 inches of mercury (e.g., 5 inches of mercury). As stated above, the vacuum shoe 78 (negative pressure) can be supplemented or replaced by the use of positive pressure from the opposite side of the web to blow the web onto the transfer fabric 74. In some implementations, other vacuum shoes can also be used to assist in drawing the wet tissue web 66 onto the surface of the transfer fabric 74. Typically, the transfer fabric 74 travels at a slower speed than the inner forming fabric 62 to enhance the machine direction (MD) and cross direction (CD) stretch of the wet tissue web 66, which generally refers to the stretch of a web in the MD or the CD (expressed as percent elongation at sample failure). For example, the relative speed difference between the two fabrics can be 1 to 30 percent, including example ranges of 5 to 30 percent and 15 percent to 20 percent, such as 17 percent. This is commonly referred to as “rush transfer.” During “rush transfer,” many of the bonds of the wet tissue web 66 are believed to be broken, thereby forcing the wet tissue web 66 to bend and fold into the depressions on the surface of the transfer fabric 74. Such molding to the contours of the surface of the transfer fabric 74 may increase the MD and CD stretch of the wet tissue web 66. Rush transfer from one fabric to another can follow the principles taught in any one of the following patents, U.S. Patent Nos. 5,667,636, 5,830,321, 4,440,597, 4,551,199, and 4,849,054.

[0075] The wet tissue web 66 is then transferred from the transfer fabric 74 to a through-air drying fabric 82 to continue drying the wet tissue web 66. The transfer fabric 74 travels at approximately the same speed as the through-air drying fabric 82. However, in alternative implementations, a second rush transfer may be performed as the wet tissue web 66 is transferred from the transfer fabric 74 to the through-air drying fabric 82. This rush transfer is referred to herein as occurring at the second position and is achieved by operating the through-air drying fabric 82 at a slower speed than the transfer fabric 74. By performing rush transfer at two distinct locations, i.e., the first and the second positions, a tissue product having increased CD stretch may be produced. In some implementations, operating the through-air drying fabric 82 at a speed slower than the speed of the transfer fabric 74 further enhances MD stretch of a resulting dried tissue web.

[0076] In addition to rush transferring the wet tissue web 66 from the transfer fabric 74 to the through-air drying fabric 82, the wet tissue web 66 may be macroscopically rearranged to conform to the surface of the through-air drying fabric 82 to give the desired bulk and appearance to the resulting dried tissue web. This can be done with the aid of a vacuum transfer roll 86 or a vacuum transfer shoe like the vacuum shoe 78. The transfer may be carried out with vacuum assistance to ensure conformation of the wet tissue web 66 to the topography of the through-air drying fabric 82. Transfer with vacuum assistance may improve macroscopic rearrangement of the wet tissue web 66 to give the desired bulk and appearance. In some implementations, the vacuum pressure at this transfer is 3 inches of mercury. The use of a separate transfer fabric 74 and through-air drying fabric 82 can offer various advantages since it allows the two fabrics to be designed specifically to address key product requirements independently. It is understood that the sheet topography can be completely changed from the transfer fabric 74 to through-air drying fabric 82, and fibers can be macroscopically rearranged (e.g., significant fiber-fiber movement) on the through-air drying fabric 82.

[0077] While supported by the through-air drying fabric 82, the wet tissue web 66 is dried to a final consistency of 94 percent based on the dry weight of the fiber or greater by a through-air dryer 90. A dried tissue web 94 exits the through-air dryer 90 and then passes through a winding nip between a reel drum 98 and a reel 102 and is wound into a roll of tissue 106 for subsequent converting, such as plying, laminating, calendaring, embossing, slitting, cutting, folding, and packaging.

[0078] In some implementations, a through-air dried papermaking process commonly referred to as “uncreped through-air dried” (“UCTAD”) is used and generally described in U.S. Patent No. 5,607,551. In some implementations, the furnish includes northern softwood kraft (NSWK) and eucalyptus hardwood kraft (EUC) using a layered headbox 54 fed by three stock chests such that the webs having three layers (two outer layers and a middle layer) are formed. The two outer layers comprise EUC and the middle layer comprises NSWK. A chemical debonder can be added to certain furnish layers.

[0079] In some implementations, the dried tissue web 94 is converted into finished product by placing a parent roll (e.g., the tissue 106 on the reel 102) of basesheet in an unwind machine. The basesheet ply is then passed through a pair of rubber-steel calender rolls with a loading force of, for example, 20 to 220 pounds per lineal inch (PLI). The calendered ply is then rolled. Subsequently, the rolled calendered ply is wound onto cardboard rolls, which is subsequently transferred to a saw and cut into individual rolls of bath tissue product.

[0080] Through-air Drying Fabric

[0081] Papermaking fabrics (e.g., the through-air drying fabric 82) may be used to produce tissue webs having good surface texture without negatively affecting the perceived softness. In some implementations, the through-air drying fabric 82 includes a three-dimensional topography pattern 112 disposed (e.g., printed onto) on a web contacting side or surface 114 of the through- air drying fabric 82. The three-dimensional pattern on the web contacting surface 114 of the fabric 82 cooperates with and structures the wet tissue web 66 during manufacturing.

[0082] As shown in FIG. 2, an additive manufacturing system 110 can be used to produce the three-dimensional surface topography pattern 112 on the web contacting surface 114 of the through-air drying fabric 82. The additive manufacturing system 110 includes a substrate 116 that supports the through-air drying fabric 82 and a printing head 118 that is structured to apply a print medium 120 to the web contacting surface 114 of the through-air drying fabric 82 to form the three-dimensional surface topography pattern 112. In some implementations, the substrate 116 is a continuous or moving substrate, a stationary substrate, or another substrate architecture. In some implementations, the additive manufacturing system 110 includes multiple printing heads 118 that can be operated simultaneously. Any additive manufacturing scheme or architecture may be used to produce the pattern onto the web contacting surface 114 of the through-air drying fabric 82. In some implementations, the additive manufacturing system 110 includes a 3D printer technology that extrudes a filament (e.g., the print medium 120) onto the continuous through-air drying fabric 82. In some implementations, the print medium 120 includes a polyethylene terephthalate glycol (PETG or PET-G), a thermoplastic copolyester (TPC), or another polymeric material.

[0083] Typical weaving and printing technology limits the designs possible commercially for use on through-air drying fabrics. For example, typical technologies are only capable of producing a continuous pattern, with the smallest bead size of 0.6mm. In some implementations, the pattern disposed on the through-air drying fabric 82 imparts that pattern into a surface of the tissue product formed thereon. Various implementations of patterns disposed on the through-air drying fabric are discussed below with respect to FIGS. 3, 5, 8, and 11. Various implementations of patterns imparted into the surface of tissue products are discussed below with respect to FIGS. 4A-4C, 6, 9, and 12.

[0084] Testing of through-air dried tissue products produced according to this disclosure surprisingly demonstrated that the through-air dried tissue products as disclosed herein provide high bulk, visually appealing aesthetics, and improved perceived softness. In some implementations, the through-air drying fabric 82 is a woven fabric upon which additional material (e.g., the print medium 120) is disposed to produce the three-dimensional surface topography pattern 112 and enhance tissue physical properties or aesthetics. The through-air drying fabric 82 may be used in the manufacture of a broad range of fibrous structures, particularly wet-laid fibrous structures and more particularly, wet-laid tissue products such as bath tissues, facial tissues, paper towels, industrial wipers, foodservice wipers, napkins, and other similar products. Further, the through-air drying fabric 82 disclosed herein is well suited for use in a wide variety of tissue manufacturing processes. For example, the fabrics may be used as TAD fabrics in either uncreped or creped applications to generate aesthetically acceptable patterns and good, bulky tissue product attributes. Alternatively, the through-air drying fabric 82 may be used as an impression fabric in wet-pressed papermaking processes.

[0085] The through-air drying fabric 82 has a textured web contacting surface 114 with a three- dimensional surface topography pattern 112 disposed thereon that extends outwardly from the web contacting surface 114. The pattern 112 also extends in the machine direction and the cross direction. As used herein, the terms “sheet contacting surface,” “sheet contacting side,” “web contacting surface,” and “web contacting side” can be used interchangeably and refer to the surface or side of the through-air drying fabric 82 that receives papermaking compositions. The opposite side or surface of the through-air drying fabric 82 is referred to as a “machine contacting surface” or “machine contacting side.”

[0086] As shown in FIG. 3, the through-air drying fabric 82 includes the three-dimensional surface topography pattern 112 protruding from the web contacting surface 114 of the through- air drying fabric 82. The three-dimensional surface topography pattern 112 includes an array of sets of shapes 122. Each set of shapes 122 includes at least a first shape 124 and a second shape 126 encompassed within and discontinuous from the first shape 124. In some implementations, each of the shapes is discontinuous from adjacent shapes. In some implementations, the first shape 124 and the second shape 126 are concentric. For example, the set of shapes 122 can include seven concentric circles each nested within and discontinuous from an adjacent concentric circle. In some implementations, the innermost circle in each set of shapes defines a diameter of 0.75 inches to 1.5 inches. In some implementations, the spacing between each concentric circle is 0.15 inches to 0.4 inches.

[0087] In some implementations, adjacent sets of shapes 122 are staggered in the machine direction. In some implementations, adjacent sets of shapes 122 are staggered in the crossmachine direction. In some implementations, at least a portion of the first shapes 124 of adjacent sets of shapes 122 intersect each other. For example, one to five of the seven concentric circles of a first set of shapes 122 can intersect an adjacent one to five of the seven concentric circles of a second, adjacent set of shapes 122. In some implementations, adjacent sets of shapes 122 arc discontinuous.

[0088] In some implementations, the first shape 124 defines a first enclosed area, and the second shape 126 defines a second enclosed area. In some implementations, the second enclosed area is fully encompassed within the first enclosed area. Typical TAD fabrics cannot be produced including the first shape 124 and the second shape 126 that are encompassed within and discontinuous from each other. Much less can traditional TAD fabrics be produced with a first enclosed area and a second enclosed area fully encompassed within the first enclosed area. This is because typical TAD fabrics are produced with a mask, a woven structure, or other continuous patterns that make it infeasible to provide a first shape 124 and a second shape 126 as disclosed herein.

[0089] In some implementations, the first shape 124 and the second shape 126 define segments that extend in a direction oblique to the machine-direction and oblique to the cross-direction. For example, portions of each circle extend oblique to both the machine-direction and the crossdirection.

[0090] In some implementations, the first shape 124 defines a first pattern height, and the second shape 126 defines a second pattern height that is the same as the first pattern height. In other implementations, the first shape 124 defines a first pattern height, and the second shape 126 defines a second pattern height that is different than the first pattern height. In some implementations, the three-dimensional surface topography pattern 112 defines a bead size or pattern height from the web contacting surface 114 of 0.4 mm to 1.5 mm. In some implementations, the first shape 124 defines a first cross-sectional profile and the second shape 126 defines a second cross-sectional profile. In some implementations, the first cross-sectional profile and the second cross-sectional profile are the same. For example, in the implementations shown, the cross-sectional profiles are semi-circular. In other implementations, the first cross- sectional profile and the second cross-sectional profile are different. For example, the first cross- sectional profile and the second cross-sectional profile may be rectangular, trapezoidal, ovoid, hyperbolic, semi-circular, and / or another profile shape as desired. The additive manufacturing process of the three-dimensional surface topography pattern 112 allows for dynamic cross- sectional profiles. In other implementations, the first shape and the second shape define non-circular shapes such as ovals, rectangles, squares, diamonds, amorphous shapes, stars, or other shapes, as desired.

[0091] In other implementations, the first shape defines a different shape than the second shape. For example, the first shape can be a circle, and the second shape can be a wavy lined ovoid.

[0092] In other implementations, each set of shapes may include two or more shapes.

[0093] Tissue Products Produced Using a Through- Air Drying Fabric

[0094] FIGS. 4A, 4B, and 4C illustrate bath tissue products 128, 130, 132 produced on the through-air dried fabric 82. The tissue products 128, 130, 132 have a three-dimensional surface topography 134 formed on the three-dimensional surface topography pattern 112 of the through- air drying fabric 82. With reference specifically to FIG. 4A and the tissue product 128, the three- dimensional surface topography 134 includes a first design element 136 and a second design element 138 encompassed within and discontinuous from the first design element 136. In some implementations, the first design element 136 and the second design element 138 are included in a set of design elements 140. In some implementations, the three-dimensional surface topography 134 includes a plurality of sets of design elements. For example, a second set of design elements 142 is shown in FIG. 4A. In some implementations, the three-dimensional surface topography 134 corresponds to the three-dimensional surface topography pattern 112 of the through-air drying fabric 82 discussed above and includes similar corresponding features that are imprinted onto the bath tissue product 128.

[0095] In some implementations, adjacent sets of design elements 140 are staggered in the machine direction and in the cross-direction. In some implementations, the first design elements 136 of adjacent sets of design elements 140 intersect. In some implementations, adjacent sets of design elements 140 are discontinuous.

[0096] In some implementations, the first design element 136 defines a first enclosed area, and the second design element 138 defines a second enclosed area. In some implementations, the second enclosed area is fully encompassed within the first enclosed area.

[0097] In some implementations, the first design element 136 and the second design element 138 are concentric. In some implementations, the first design element 136 and the second design element 138 are circular. In some implementations, the first design element 136 and the second design element 138 define segments that extend in a direction oblique to a machine-direction and oblique to a cross -direction. In some implementations, the first design element 136 defines a first depth of impression, and wherein the second design element 138 defines a second depth of impression that is the same as the first depth of impression. In other implementations, the first design element 136 defines a first depth of impression, and wherein the second design element 138 defines a second depth of impression that is different than the first depth of impression.

[0098] In some implementations, the pattern comprises a plurality discrete design elements 140 arranged to prevent adjacent tissue webs or a tissue product from nesting together. In this regard, various anti-nesting design elements may be incorporated into the pattern. The concentric circles shown in FIGS. 4A-4C are overlapping or intersecting in a pattern that inhibits nesting. In other words, the oblique segments of the first design element 136 and the second design element 138 are not aligned and inhibit nesting. In tissue products formed on typical TAD fabrics having continuous patterns that run generally in the machine-direction, nesting can occur. One advantage of patterns comprising design elements arranged in a non-nesting configuration, such as the tissue products (e.g., the tissue products 128, 130, 132) disclosed herein, is that a stack caliper of the tissue product is greater than a corresponding stack caliper of sheets produced with nesting or partially nesting patterns. FIGS. 4B and 4C illustrate two additional tissue products 130, 132 formed on different sections of the through- air drying fabric 82 and include features similar’ to those of the tissue product 128 discussed above.

[0099] FIG. 5 is a close-up view of a through-air dried fabric 146 according to another implementation. A three-dimensional surface topography pattern 112’ of the through-air dried fabric 146 is similar to the three-dimensional surface topography pattern 112 of the through-air dried fabric 82 but has a different overlap pattern. The three-dimensional surface topography pattern 112’ is produced with PETG.

[0100] FIG. 6 is a photograph of a tissue product in the form of a roll of a bath tissue web 150 that was formed on the through-air dried fabric 146 and includes a three-dimensional surface topography 154, which is imparled by the three-dimensional surface topography pattern 112’ on the through-air dried fabric 146.

[0101] FIG. 7 shows microscopy scans of a portion of the bath tissue web 150 taken using a Keyence microscope. To gain an understanding of the topography of each product, a Keyence VHX-5000 Digital Microscope was used to measure the height of the three-dimensional surface topography of the bath tissue web 150. The bath tissue web 150 was placed under a glass microscope slide, which was weighted, and a three dimensional (3D) stitched image was taken of the area under the glass slide. Once the 3D image was taken, a line was drawn across the middle machine direction (MD) position of the image, and the average function was used to create ten lines spaced at 5 pm increments from which CD profile of the product was generated. In some implementations, the depth of impression of the first design element 136 and the second design element 138 is 200 pm to 1500 pm. In some implementations, the depth of impression of the first design element 136 and the second design element 138 is 340 pm to 345 pm.

[0102] FIG. 8 is a close-up view of another implementation of a through-air dried fabric 174. A three-dimensional surface topography pattern 112” of the through-air dried fabric 174 is similar to the three-dimensional surface topography pattern 112 of the through-air dried fabric 82 but has a different overlap pattern. The three-dimensional surface topography pattern 112” is produced with TPC.

[0103] FIG. 9 is a photograph of a tissue product in the form of a roll of a bath tissue web 178 formed using the through-air dried fabric 174 and includes a three-dimensional surface topography 180, which is imparted by the topography pattern 112” on the fabric 174.

[0104] FIG. 10 shows microscopy scans of a portion of the bath tissue web 178 taken using a Keyence microscope. In some implementations, the depth of impression of the first design element and the second design element of the three-dimensional surface topography 180 is 200 pm to 1500 pm. In some implementations, the depth of impression of the first design element and the second design element is 390 pm to 485 pm.

[0105] FIG. 11 is a close-up view of another implementation of a through-air dried fabric 182. A three-dimensional surface topography pattern 112”’ of the through-air dried fabric 182 is similar to the three-dimensional surface topography pattern 112 of the through-air dried fabric 82 but has a different overlap pattern. The three-dimensional surface topography pattern 112”’ is produced with TPC.

[0106] FIG. 12 is a photograph of a tissue product in the form of a roll of a bath tissue web 186 formed using the through-air dried fabric 182 and includes a three-dimensional surface topography 190, which is imparted by the topography pattern 112’” on the fabric 182.

[0107] FIG. 13 shows microscopy scans of a portion of the bath tissue web 186 taken using a Keyence microscope. In some implementations, the depth of impression of the first design element and the second design element is 200 m to 1500 pm. In some implementations, the depth of impression of the first design clement and the second design clement is 320 pm to 325 pm.

[0108] Method of Forming a Tissue Product

[0109] A method of forming a tissue product (e.g., any of the bath tissue webs 128, 130, 132, 150, 178, 186) includes providing a through-air drying fabric (e.g., any of the through-air drying fabrics 82, 146, 174, 182) having a web contacting surface and an additive manufactured, three- dimensional topography (e.g., any of the three-dimensional surface topography patterns 112, 112’, 112”, 112”’) disposed onto the web contacting surface. The topography defines a first shape (e.g., first shape 124) and a second shape (e.g., second shape 126) encompassed within and discontinuous from the first shape. The method further includes forming an aqueous suspension of fibers (e.g., using the papermaking headbox 54), depositing the aqueous suspension of fibers onto a forming fabric (e.g., outer forming fabric 58, the inner forming fabric 62) to form a wet web (e.g., wet tissue web 66), dewatering the wet web (e.g., with the vacuum shoe 78 and transfer fabric 74), transferring the dewatered wet web onto the through-air drying fabric (e.g., with the vacuum transfer roll 86), and through-air drying (e.g., with the through-air dryer 90) the dewatered wet web to form the tissue product including a through-air dried tissue ply (e.g., the dried tissue web 94) including an imprinted three-dimensional topography (e.g., any of the three- dimensional surface topographies 134, 180, 190) imparted to the through-air dried tissue ply by the through-air drying fabric. The three-dimensional topography defines a first design element (e.g., the first design element 136) corresponding to the first shape of the through-air drying fabric, and a second design element (e.g., the second design element 138) corresponding to the second shape of the through-air drying fabric.

[0110] In some implementations, the through-air dried tissue ply may be subjected to further converting to produce the tissue product. For example, the through-air dried tissue ply may undergo calendering and / or other processes.

[0111] Examples Despite having a three-dimensional surface topography, the tissue products (e.g., any of the bath tissue webs 150, 178, 186) produced using a through-air drying fabric (c.g., any of the through-air drying fabrics 82, 146, 174, 182) are not overly rough and remain highly flexible. Sample tissue products were produced according to this disclosure using the through-air drying fabric 82 and compared to a control tissue product produced on patterned TAD fabric defining continuous ridges extending in the machine direction.

[0112] Table 1 indicates the forming conditions for making the sample tissue products using the through- air drying fabric 82 and the control tissue products. Table 1

[0113] Table 2 below provides test results from the sample tissue products produced with the through-air drying fabric 82 (referred to as “Discontinuous Pattern”) and the control tissue product. Table 2

[0114] As shown in Table 2, the tissue products produced with the through-air drying fabric 82 showed faster wet out times than the control tissue products while maintaining a similar absorbent capacity. The sheet caliper of the tissue products produced using the through-air drying fabric 82 were similar to the sheet caliper of the control tissue products, but the stack caliper of the tissue products produced using the through-air drying fabric 82 was larger than the stack caliper of the control tissue products. In some implementations, the improved stack caliper is attributed to the non-nesting configuration of the three-dimensional surface topography 134. In some implementations, a sheet caliper of the tissue products with the discontinuous pattern is 430 pm to 500 pm. In some implementations, a stack caliper of ten sheets of the tissue products with the discontinuous pattern is above 4200 pm.

[0115] In some implementations, a wet-out time of the tissue product is 5.1 seconds to 6.4 seconds. In some implementations, an absorbent capacity of the tissue product is 9.2 g / g to 11.3 g / g. In some implementations, a sheet caliper is 430 pm to 500 pm. In some implementations, a stack caliper of ten sheets is above 4200 pm. In some implementations, a firmness of the tissue product is 5.3 mm to 6.6 mm. In some implementations, a sheet bulk of the tissue product is 9.5 cc / g to 11.7 cc / g. Table 3

[0116] Table 3 reports values of various properties of the sample tissue products. As shown in Table 3, the peak load of the tissue products with the discontinuous pattern was higher in the cross-direction than the control tissue products, as determined by a strip tensile detaching strength test. The peak stretch percent of the tissue products with the discontinuous pattern was lower than the control tissue products in both the machine-direction and the cross -direction.

[0117] In some implementations, a dry machine-direction tensile of the tissue product is 1287 g / 3” to 1573 g / 3”. In some implementations, a dry cross-direction tensile of the tissue product is 688 g / 3” to 841 g / 3”. In some implementations, a tensile ratio of the tissue product is 1.6 to 2.1.

[0118] In some implementations, a dry cross -direction TEA of the tissue product is 5.3 gf*cm / cmA2 to 6.6 gf*cm / cmA2. In some implementations, a dry cross-direction tear of the tissue product is 7.4 cN to 9.1 cN. In some implementations, a wet cross -direction tensile of the tissue product is 140 gf to 172 gf. Table 4

[0119] As shown in Table 4, the bending stiffness of the sample tissue products with the discontinuous pattern was greater than the control tissue products. The wet bursting strength of the tissue products with the discontinuous pattern was also greater than the control tissue products. In some implementations, an average geometric mean tensile (GMT) of the tissue product with the discontinuous pattern is 940 g / 3” to 1200 g / 3”. In some implementations, a GM slope of the tissue product is 10.4 kg to 12.8 kg. In some implementations, a stiffness index of the tissue product is 9.9 to 12.2. In some implementations, a wet burst of the tissue product is 157 gf to 191 gf.

[0120] Test Methods

[0121] Wet-Out or wet-out time is measured by first allowing the test product to equilibrate to ambient conditions for at least four hours at 23+ / -3.00°C. and 50+ / -5 percent relative humidity. Twenty (20) sheets are stacked and cut to a 60 x 60 mm (+3 mm) square using a device capable of cutting to the specified dimensions such as a Hudson Machinery, or equivalent. The square is then fixed in each comer by staples delivered by a standard, commercially available manual office stapler. The staples are placed diagonally across each corner far enough into the sheet so that the staples are completely contacting the tissue sheets, staples should not wrap the corner of the sample. The sample is then held horizontally and approximately 25 mm (1 inch) over a container containing distilled or de-ionized water at 23.0+-3.0°C. The container should be of sufficient size and depth to ensure that the saturated specimen does not contact the sides, bottom of the container, and the top surface of the water at the same time. The container should contain a minimum depth of 51 mm of water to ensure complete saturation of the test specimen and this depth should be maintained throughout the testing. The specimen is then dropped flat onto the water surface and a timing device is started when the specimen contacts the water surface. As soon as the specimen is completely saturated, stop the timing device and record the absorbency wet out time in seconds.

[0122] Absorbent capacity is determined by first cutting 20 sheets of a sample, each sheet measuring 3"x3" and stapling the 20 sheets together at the edges to form a test specimen. A test specimen is then weighed. The weighed specimen is then soaked in a pan of test fluid (e.g., paraffin oil or water) for three minutes. The test fluid should be at least 2 inches (5.08 cm) deep in the pan. The specimen is removed from the test fluid and allowed to drain while hanging in a “diamond” shaped position (i.e., with one corner at the lowest point). The specimen is allowed to drain for three minutes for water and for five minutes for oil. After the allotted drain time the specimen is placed in a weighing dish and then weighed. Absorbent Capacity (g)=wet weight (g)-dry weight (g) and Specific Absorbent Capacity (g / g)=Absorbent Capacity (g) / dry weight (g).

[0123] Basis weight is tested by first conditioning all samples under TAPPI conditions (23 ± 1°C and 50 ± 2 percent relative humidity) for a minimum of 4 hours. Basis weight is measured by selecting sixteen (16) finished tissue products (also referred to as sheets) of the sample and making two (2) stacks of eight (8) sheets. In the event the sample consists of perforated sheets of bath or towel tissue, the perforations must be aligned on the same side when stacking the usable units. A precision cutter is used to cut each stack into exactly 7.62x7.62 cm (3.0x3.0 inch) squares. The two stacks of cut squares are combined to make a basis weight pad of sixteen (16) squares thick. Alternatively, the basis weight pad consists of one stack having 9 sheets of 10.16 cm x 10.16 cm (4.0 inch x 4.0 inch) squares. The basis weight pads are placed in a commercial oven (e.g. Blue M Industrial Ovens serial #10089811 from Thermal Product Solutions or equivalent) maintained at 105 ±2 °C for 60 ±5 minutes. The basis weight pad is then weighed on a top loading balance with a minimum resolution of 0.01 grams. The top loading balance must be protected from air drafts and other disturbances using a draft shield. Weights arc recorded when the readings on the top loading balance become constant. The mass of the sample (grams) per unit area (square meters) is calculated and reported as the basis weight, having units of grams per square meter (gsm).

[0124] Tensile testing is conducted on a tensile testing machine maintaining a constant rate of elongation and the width of each specimen tested is 3 inches. Testing is conducted under TAPPI conditions. Prior to testing samples are conditioned under TAPPI conditions (23 ± I °C and 50 ± 2 percent relative humidity) for at least 4 hours and then cutting a 3 ± 0.05 inches (76.2 ± 1.3 mm) wide strip in either the machine direction (MD) or cross-machine direction (CD) orientation using a JDC Precision Sample Cutter (Thwing-Albert Instrument Company, Philadelphia, PA, Model No. JDC 3-10, Serial No. 37333) or equivalent. The instrument used for measuring tensile strengths was an MTS Systems Sintech 1 IS, Serial No. 6233. 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 either a 50 Newton or 100 Newton maximum, depending on the strength of the sample being tested, such that the majority of peak load values fall between 10 to 90 percent of the load cell’s full-scale value. The gauge length between jaws was 4 ± 0.04 inches (101.6 ± 1 mm) for facial tissue and towels and 2 ± 0.02 inches (50.8 ± 0.5 mm) for bath tissue. The crosshead speed was 10 ± 0.4 inches / min (254 ±1 mm / min), and the break sensitivity was set at 65 percent. The sample was placed in the jaws of the instrument, centered both vertically and horizontally. The test was then started and ended when the specimen broke. The peak load was recorded as either the “MD tensile strength” or the “CD tensile strength” of the specimen depending on direction of the sample being tested. Ten representative specimens were tested for each product or sheet and the arithmetic average of all individual specimen tests was recorded as the appropriate MD or CD tensile strength having units of grams per three inches (g / 3”). Tensile energy absorbed (TEA) and slope are also calculated by the tensile tester. TEA is reported in units of g'cm / cm2and slope is recorded in units of kilograms (kg). Both TEA and Slope are directionally dependent and thus MD and CD directions are measured independently.

[0125] Caliper is measured in accordance with TAPPI test methods Test Method T 580 pm- 12 “Thickness (caliper) of towel, tissue, napkin and facial products.” The micrometer used for carrying out caliper measurements is an Emveco 200- A Tissue Caliper Tester (Emveco, Inc., Newberg, OR). The micrometer has a load of 2 kilopascals, a pressure foot area of 2,500 square millimeters, a pressure foot diameter of 56.42 millimeters, a dwell time of 3 seconds and a lowering rate of 0.8 millimeters per second.

[0126] Single sheet caliper, also referred to herein as sheet caliper, is measured as described above using a single sheet, not ply, of tissue web or product. When measuring the sheet caliper of a rolled bath tissue product, two attached consecutive sheets are dispensed from the roll to ensure a sample having a size of at least 102 mm x 102 mm (4 inches x 4 inches).

[0127] The caliper of a stack of sheets, also referred to herein as stack caliper, is measured using ten sheets of tissue web or product, keeping the same side up and the machine direction of the sheets aligned uniformly. When measuring the stack caliper of a rolled bath tissue product two attached consecutive sheets are dispensed from the roll to ensure a sample having a size of at least 102 mm x 102 mm (4 inches x 4 inches) and then forming the stack keeping the same side up and the machine direction of the sheets aligned uniformly.

[0128] The firmness is determined using the Kershaw Test. The apparatus for conducting the Kershaw Test is available from Kershaw Instrumentation, Inc., Swedesboro, N.J. and is known as a Model RDT-101 Roll Density Tester. Briefly, a tissue product to be measured is supported as a roll on a spindle. A traverse table moves toward the roll. Mounted to the traverse table is a sensing probe. The motion of the traverse table causes the sensing probe to make contact with the roll. The instant the sensing probe contacts the roll, the force exerted on a load cell will exceed the low set point of 6 grams and the displacement display will be zeroed and begin indicating the penetration of the probe. When the force exerted on the sensing probe exceeds the high set point of 687 grams, the traverse table will stop and the displacement display will indicate the penetration in millimeters. The tester will record this reading. Next the tester will rotate the roll 90° on the spindle and repeat the test. The roll firmness value is the average of the two readings. The test is performed in a controlled environment of 73.4±1.8 °F and 50±2% relative humidity. The rolls to be tested need to be introduced to this environment at least 4 hours before testing.

[0129] Burst or “burst strength” is measured using an EJA Burst Tester (series #50360, commercially available from Thwing- Albert Instrument Company, Philadelphia, Pa.). The test procedure is according to TAPPI T570 pm-00 except the test speed. The test specimen is clamped between two concentric rings whose inner diameter defines the circular area under test. A penetration assembly, the top of which is a smooth, spherical steel ball, is arranged perpendicular to and centered under the rings holding the test specimen. The penetration assembly is raised at 6 inches per minute such that the steel ball contacts and eventually penetrates the test specimen to the point of specimen rupture. The maximum force applied by the penetration assembly at the instant of specimen rupture is reported as the burst strength in grams force (gf) of the specimen.

[0130] The penetration assembly consists of a spherical penetration member, which is a stainless- steel ball with a diameter of 0.625+0.002 inches (15.88+0.05 mm) finished spherical to 0.00004 inches (0.001 mm). The spherical penetration member is permanently affixed to the end of a 0.375+0.010 inch (9.525+0.254 mm) solid steel rod. A 2000 gram load cell is used and 50 percent of the load range is selected. The distance of travel of the probe is such that the upper most surface of the spherical ball reaches a distance of 1.375 inches (34.9 mm) above the plane of the sample clamped in the test. A means to secure the test specimen for testing consisting of upper and lower concentric rings of approximately 0.25 inches (6.4 mm) thick aluminum between which the sample is firmly held by pneumatic clamps operated under a filtered air source at 60 psi. The clamping rings are 3.50+0.01 inches (88.9+0.3 mm) in internal diameter and approximately 6.5 inches (165 mm) in outside diameter. The clamping surfaces of the clamping rings are coated with a commercial grade of neoprene approximately 0.0625 inches (1.6 mm) thick having a Shore hardness of 70-85 (A scale). The neoprene needs not cover the entire surface of the clamping ring but is coincident with the inner diameter, thus having an inner diameter of 3.50+0.01 inches (88.9+0.3 mm) and is 0.5 inches (12.7 mm) wide, thus having an external diameter of 4.5+0.01 inches (114+0.3 mm). For each test, a total of 3 sheets of product are combined.

[0131] The sheets are stacked on top of one another in a manner such that the machine direction of the sheets is aligned. Where samples comprise multiple plies, the plies are not separated for testing. In each instance the test sample comprises 3 sheets of product. For example, if the product is a 2-ply tissue product, 3 sheets of product, totaling 6 plies are tested. If the product is a single ply tissue product, then 3 sheets of product totaling 3 plies are tested.

[0132] Samples are conditioned under TAPPI conditions for a minimum of four hours and cut into 127x127+5 mm squares. For wet burst measurement, after conditioning, the samples were wetted for testing with 0.5 mL of deionized water dispensed with an automated pipette. The wet sample is tested immediately after insulting. The peak load (gf) and energy to peak (g-cm) are recorded and the process repeated for all remaining specimens. A minimum of five specimens arc tested per sample and the peak load average of five tests is reported.

[0133] Tear testing was carried out in accordance with TAPPI test method T-414 “Internal Tearing Resistance of Paper (Elmendorf-type method)” using a falling pendulum instrument such as Lorentzen & Wettre Model SE 009. Tear strength is directional, and MD and CD tear are measured independently.

[0134] More particularly, a rectangular' test specimen of the sample to be tested is cut out of the tissue product or tissue base sheet such that the test specimen measures 63+0.15 mm (2.5+0.006 inches) in the direction to be tested (such as the MD or CD direction) and between 73 and 114 mm (2.9 and 4.6 inches) in the other direction. The specimen edges must be cut parallel and perpendicular to the testing direction (not skewed). Any suitable cutting device, capable of the prescribed precision and accuracy, can be used. The test specimen should be taken from areas of the sample that are free of folds, wrinkles, crimp lines, perforations or any other distortions that would make the test specimen abnormal from the rest of the material.

[0135] The number of plies or sheets to test is determined based on the number of plies or sheets required for the test results to fall between 20 to 80 percent on the linear range scale of the tear tester and more preferably between 20 to 60 percent of the linear range scale of the tear tester. The sample preferably should be cut no closer than 6 mm (0.25 inch) from the edge of the material from which the specimens will be cut. When testing requires more than one sheet or ply, the sheets are placed facing in the same direction.

[0136] The test specimen is then placed between the clamps of the falling pendulum apparatus with the edge of the specimen aligned with the front edge of the clamp. The clamps are closed, and a 20-millimeter slit is cut into the leading edge of the specimen usually by a cutting knife attached to the instrument. For example, on the Lorentzen & Wettre Model SE 009, the slit is created by pushing down on the cutting knife lever until it reaches its stop. The slit should be clean with no tears or nicks as this slit will serve to start the tear during the subsequent test.

[0137] The pendulum is released and the tear value, which is the force required to completely tear the test specimen, is recorded. The test is repeated a total of ten times for each sample and the average of the ten readings reported as the tear' strength. Tear strength is reported in units of grams of force (gf). The average tear value is the tear strength for the direction (MD or CD) tested. The “geometric mean tear strength” is the square root of the product of the average MD tear strength and the average CD tear strength. The Lorcntzcn & Wcttrc Model SE 009 has a setting for the number of plies tested. Some testers may need to have the reported tear strength multiplied by a factor to give a per ply tear strength. For base sheets intended to be multiple ply products, the tear results are reported as the tear of the multiple ply product and not the single ply base sheet. This is done by multiplying the single ply base sheet tear value by the number of plies in the finished product. Similarly, multiple ply finished product data for tear is presented as the tear strength for the finished product sheet and not the individual plies. A variety of means can be used to calculate, but, in general, will be done by inputting the number of sheets to be tested rather than the number of plies to be tested into the measuring device. For example, two sheets would be two 1 -ply sheets for 1 -ply product and two 2-ply sheets (4-plies) for 2-ply products.

[0138] While tissue webs, and tissue products comprising the same, have been described in detail with respect to the specific implementations thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these implementations.

[0139] Although several aspects of the disclosure have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects of the disclosure will come to mind to which the disclosure pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. Thus, it is understood that the disclosure is not limited to the specific aspects disclosed hereinabove and that many modifications and other aspects are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense and not for the purposes of limiting the described disclosure nor the claims which follow. Therefore, we claim as our disclosure all that comes within the scope and spirit of these claims.

[0140] Exemplary Implementations

[0141] Example 1. A tissue product comprising at least one through-air dried tissue ply having a first surface and a second surface, the first surface having a three-dimensional pattern disposed thereon, the three-dimensional pattern comprising a first design element and a second design element encompassed within and discontinuous from the first design element.

[0142] Example 2. The tissue product of Example 1, wherein the first design element defines a first enclosed area, and wherein the second design element defines a second enclosed area.

[0143] Example 3. The product of Example 2, wherein the second enclosed area is fully encompassed within the first enclosed area.

[0144] Example 4. The tissue product of any of the above Examples, wherein the first design element and the second design element are concentric.

[0145] Example 5. The tissue product of any of the above Examples, wherein the first design element and the second design element are circular.

[0146] Example 6. The tissue product of any of the above Examples, wherein the first design element and the second design element define segments that extend in a direction oblique to a machine-direction and oblique to a cross-machine direction.

[0147] Example 7. The tissue product of any of the above Examples, wherein the first design element defines a first depth of impression, and wherein the second design element defines a second depth of impression that is the same as the first depth of impression.

[0148] Example 8. The tissue product of any of the above Examples, wherein the first design element and the second design element define a set of design elements, and wherein the three- dimensional pattern includes a plurality of sets of design elements.

[0149] Example 9. The tissue product of Example 8, wherein adjacent sets of design elements are staggered in a machine direction and in a cross -direction.

[0150] Example 10. The tissue product of any of Examples 8-9, wherein the first design elements of adjacent sets of design elements intersect.

[0151] Example 11. The tissue product of any of Examples 8-10, wherein adjacent sets of design elements are discontinuous.

[0152] Example 12. The tissue product of any of Examples 8-11, wherein the plurality of sets of design elements are non-nesting.

[0153] Example 13. The tissue product of any of the above Examples, wherein a wet-out time of the tissue product is 5.1 seconds to 6.4 seconds.

[0154] Example 14. The tissue product of any of the above Examples, wherein an absorbent capacity of the tissue product is 9.2 g / g to 11.3 g / g. Example 15. The tissue product of any of the above Examples, wherein a sheet caliper is 430 pm to 500 pm.

[0155] Example 16. The tissue product of any of the above Examples, wherein a stack caliper of ten sheets is above 4200 pm.

[0156] Example 17. The tissue product of any of the above Examples, wherein a firmness of the tissue product is 5.3 mm to 6.6 mm.

[0157] Example 18. The tissue product of any of the above Examples, wherein a sheet bulk of the tissue product is 9.5 cc / g to 11.7 cc / g.

[0158] Example 19. The tissue product of any of the above Examples, wherein a dry machinedirection tensile of the tissue product is 1287 g / 3” to 1573 g / 3”.

[0159] Example 20. The tissue product of any of the above Examples, wherein a dry crossdirection tensile of the tissue product is 688 g / 3” to 841 g / 3”.

[0160] Example 21. The tissue product of any of the above Examples, wherein a tensile ratio of the tissue product is 1.6 to 2.1.

[0161] Example 22. The tissue product of any of the above Examples, wherein a dry crossdirection TEA of the tissue product is 5.3 gf*cm / cmA2 to 6.6 gf*cm / cmA2.

[0162] Example 23. The tissue product of any of the above Examples, wherein a dry crossdirection tear of the tissue product is 7.4 cN to 9.1 cN.

[0163] Example 24. The tissue product of any of the above Examples, wherein a wet crossdirection tensile of the tissue product is 140 gf to 172 gf.

[0164] Example 25. The tissue product of any of the above Examples, wherein a geometric mean tensile of the tissue product is 940 g / 3” to 1200 g / 3”.

[0165] Example 26. The tissue product of any of the above Examples, wherein a GM slope of the tissue product is 10.4 kg to 12.8 kg.

[0166] Example 27. The tissue product of any of the above Examples, wherein a stiffness index of the tissue product is 9.9 to 12.2.

[0167] Example 28. The tissue product of any of the above Examples, wherein a wet burst of the tissue product is 157 gf to 191 gf.

[0168] Example 29. The tissue product of any of the above Examples, wherein the first design element and the second design element are molded by corresponding shapes defined in a through-air drying fabric. Example 30. The tissue product of any of the above Examples, wherein the tissue product is free from embossments.

[0169] Example 31. A through-air drying fabric for forming a tissue product, the through-air drying fabric comprising: a web contacting surface; and an additive manufactured, three- dimensional topography disposed on the web contacting surface, the three-dimensional topography defining a first shape, and a second shape encompassed within and discontinuous from the first shape.

[0170] Example 32. The through-air drying fabric of Example 31, wherein the first shape and the second shape are concentric circles.

[0171] Example 33. The through-air drying fabric of any of Examples 31-32, wherein the first shape and the second shape define a set of shapes, wherein the three-dimensional topography includes a plurality of sets of shapes, and wherein the plurality of sets of shapes are non-nesting.

[0172] Example 34. The through-air drying fabric of any of Examples 31-33, wherein the first shape defines a first enclosed area, and wherein the second shape defines a second enclosed area.

[0173] Example 35. The through-air drying fabric of Example 34, wherein the second enclosed area is fully encompassed within the first enclosed area.

[0174] Example 36. The through-air drying fabric of any of Examples 31-35, wherein the first shape and the second shape define segments that extend in a direction oblique to a machinedirection and oblique to a cross-direction.

[0175] Example 37. The through-air drying fabric of any of Examples 31-36, wherein the first shape defines a first pattern height, and wherein the second shape defines a second pattern height that is the same as the first pattern height.

[0176] Example 38. The through-air drying fabric of any of Examples 31-37, wherein the first shape and the second shape are included in a set of shapes, and wherein the three-dimensional topography includes a plurality of sets of shapes.

[0177] Example 39. The through-air drying fabric of Example 38, wherein adjacent sets of shapes are staggered in a machine direction and in a cross-direction.

[0178] Example 40. The through-air drying fabric of any of Examples 38-39, wherein the first shapes of adjacent sets of shapes intersect.

[0179] Example 41. The through-air drying fabric of any of Examples 38-40, wherein adjacent sets of shapes are discontinuous. Example 42. The through-air drying fabric of any of Examples 38-41 , wherein the plurality of sets of shapes arc non-nesting.

[0180] Example 43. The through-air drying fabric of any of Examples 31-42, wherein the through-air drying fabric is configured to produce the tissue product having a geometric mean tensile of the tissue product is 950 g / 3” to 1200 g / 3”.

[0181] Example 44. The through-air drying fabric of any of Examples 31-43, wherein the through-air drying fabric is configured to produce the tissue product having a sheet caliper is 430 pm to 500 pm.

[0182] Example 45. The through-air drying fabric of any of Examples 31-44, wherein the through-air drying fabric is configured to produce the tissue product having a stack caliper of ten sheets is above 4200 pm.

[0183] Example 46. A method of forming a through-air dried tissue ply, the method comprising: providing a through-air drying fabric having a web contacting surface and comprising an additive manufactured, three-dimensional topography disposed on the web contacting surface, the three-dimensional topography defining a first shape and a second shape encompassed within and discontinuous from the first shape; forming an aqueous suspension of fibers; depositing the aqueous suspension of fibers onto a forming fabric to form a wet web; dewatering the wet web; transferring the dewatered wet web onto the web contacting surface of the through-air drying fabric; and through-air drying the dewatered wet web to form the through- air dried tissue ply, the through-air dried tissue ply including an imprinted three-dimensional topography imparted to the through-air dried tissue ply by the topography disposed on the web contacting surface of the through-air drying fabric, the three-dimensional topography defining a first design element corresponding to the first shape of the through-air drying fabric and a second design element corresponding to the second shape of the through-air drying fabric.

[0184] Example 47. The method of Example 46, wherein the first design element defines a first enclosed area, wherein the second design element defines a second enclosed area; and wherein the second enclosed area is fully encompassed within the first enclosed area.

[0185] Example 48. The method of Example 47, wherein the second enclosed area is fully encompassed within the first enclosed area.

[0186] Example 49. The method of any of Examples 46-48, wherein the first design element and the second design element are concentric. Example 50. The method of any of Examples 46-49, wherein the first design element and the second design element arc circular.

[0187] Example 51. The method of any of Examples 46-50, wherein the first design element and the second design element define segments that extend in a direction oblique to a machinedirection and oblique to a cross-direction.

[0188] Example 52. The method of any of Examples 46-51, wherein the first design element defines a first depth of impression, and wherein the second design element defines a second depth of impression that is the same as the first depth of impression.

[0189] Example 53. The method of any of Examples 46-52, wherein the first design element and the second design element define a set of design elements, and wherein the three- dimensional topography includes a plurality of sets of design elements.

[0190] Example 54. The method of Example 53, wherein adjacent sets of design elements are staggered in a machine direction and in a cross-direction.

[0191] Example 55. The method of any of Examples 53-54, wherein the first design elements of adjacent sets of design elements intersect.

[0192] Example 56. The method of any of Examples 53-55, wherein adjacent sets of design elements are discontinuous.

[0193] Example 57. The method of any of Examples 53-56, wherein the plurality of sets of design elements are non-nesting.

[0194] Example 58. The method of any of Examples 46-57, wherein a geometric mean tensile of the through-air dried tissue ply is 950 g / 3” to 1200 g / 3”.

[0195] Example 59. The method of any of Examples 46-58, wherein a sheet caliper is 430 pm to 500 pm.

[0196] Example 60. The method of any of Examples 46-59, wherein a stack caliper of ten sheets is above 4200 pm.

Claims

CLAIMS1. A tissue product comprising at least one through-air dried tissue ply having a first surface and a second surface, the first surface having a three-dimensional pattern disposed thereon, the three-dimensional pattern comprising: a first design element, and a second design element encompassed within and discontinuous from the first design element.

2. The tissue product of claim 1, wherein the first design element defines a first enclosed area, and wherein the second design element defines a second enclosed area.

3. The tissue product of claim 2, wherein the second enclosed area is fully encompassed within the first enclosed area.

4. The tissue product of claim 1, wherein the first design element and the second design element are concentric.

5. The tissue product of claim 1, wherein the first design element and the second design element are circular.

6. The tissue product of claim 1, wherein the first design element and the second design element define segments that extend in a direction oblique to a machine-direction and oblique to a cross-machine direction.

7. The tissue product of claim 1, wherein the first design element defines a first depth of impression, and wherein the second design element defines a second depth of impression that is the same as the first depth of impression.

8. The tissue product of claim 1 , wherein the first design element and the second design element define a set of design elements, and wherein the three-dimensional pattern includes a plurality of sets of design elements.

9. The tissue product of claim 8, wherein adjacent sets of design elements are staggered in a machine direction and in a cross-direction.

10. The tissue product of claim 8, wherein the first design elements of adjacent sets of design elements intersect.

11. The tissue product of claim 8, wherein adjacent sets of design elements are discontinuous.

12. The tissue product of claim 8, wherein the plurality of sets of design elements are nonnesting.

13. The tissue product of claim 1, wherein a wet-out time of the tissue product is 5.1 seconds to 6.4 seconds.

14. The tissue product of claim 1, wherein an absorbent capacity of the tissue product is 9.2 g / g to 11.3 g / g.

15. The tissue product of claim 1, wherein a sheet caliper is 430 pm to 500 pm.

16. The tissue product of claim 1, wherein a stack caliper of ten sheets is above 4200 pm.

17. The tissue product of claim 1, wherein a firmness of the tissue product is 5.3 mm to 6.6 mm.

18. The tissue product of claim 1, wherein a sheet bulk of the tissue product is 9.5 cc / g to 11.7 cc / g.

19. The tissue product of claim 1, wherein a dry machine-direction tensile of the tissue product is 1287 g / 3” to 1573 g / 3”.

20. The tissue product of claim 1, wherein a dry cross-direction tensile of the tissue product is 688 g / 3” to 841 g / 3”.

21. The tissue product of claim 1, wherein a tensile ratio of the tissue product is 1.6 to 2.1.

22. The tissue product of claim 1, wherein a dry cross-direction TEA of the tissue product is5.3 gf*cm / cmA2 to 6.6 gf*cm / cmA2.

23. The tissue product of claim 1, wherein a dry cross-direction tear of the tissue product is7.4 cN to 9.1 cN.

24. The tissue product of claim 1, wherein a wet cross-direction tensile of the tissue product is 140 gf to 172 gf.

25. The tissue product of claim 1, wherein a geometric mean tensile of the tissue product is 940 g / 3” to 1200 g / 3”.

26. The tissue product of claim 1, wherein a GM slope of the tissue product is 10.4 kg to 12.8 kg-27. The tissue product of claim 1, wherein a stiffness index of the tissue product is 9.9 to 12.2.

28. The tissue product of claim 1, wherein a wet burst of the tissue product is 157 gf to 191 gf.

29. The tissue product of claim 1 , wherein the first design element and the second design element arc molded by corresponding shapes defined in a through-air drying fabric.

30. The tissue product of claim 1, wherein the tissue product is free from embossments.

31. A through-air drying fabric for forming a tissue product, the through-air drying fabric comprising: a web contacting surface; and an additive manufactured, three-dimensional topography disposed on the web contacting surface, the three-dimensional topography defining a first shape, and a second shape encompassed within and discontinuous from the first shape.

32. The through-air drying fabric of claim 31, wherein the first shape and the second shape are concentric circles.

33. The through-air drying fabric of claim 31, wherein the first shape and the second shape define a set of shapes, wherein the three-dimensional topography includes a plurality of sets of shapes, and wherein the plurality of sets of shapes are non-nesting.

34. The through-air drying fabric of claim 31, wherein the first shape defines a first enclosed area, and wherein the second shape defines a second enclosed area.

35. The through-air drying fabric of claim 34, wherein the second enclosed area is fully encompassed within the first enclosed area.

36. The through-air drying fabric of claim 31, wherein the first shape and the second shape define segments that extend in a direction oblique to a machine-direction and oblique to a crossdirection.

37. The through-air drying fabric of claim 31, wherein the first shape defines a first pattern height, and wherein the second shape defines a second pattern height that is the same as the first pattern height.

38. The through-air drying fabric of claim 31, wherein the first shape and the second shape are included in a set of shapes, and wherein the three-dimensional topography includes a plurality of sets of shapes.

39. The through-air drying fabric of claim 38, wherein adjacent sets of shapes are staggered in a machine direction and in a cross-direction.

40. The through-air drying fabric of claim 38, wherein the first shapes of adjacent sets of shapes intersect.

41. The through-air drying fabric of claim 38, wherein adjacent sets of shapes are discontinuous.

42. The through-air drying fabric of claim 38, wherein the plurality of sets of shapes are nonnesting.

43. The through-air drying fabric of claim 31, wherein the through-air drying fabric is configured to produce the tissue product having a geometric mean tensile of the tissue product is 950 g / 3” to 1200 g / 3”.

44. The through-air drying fabric of claim 31, wherein the through-air drying fabric is configured to produce the tissue product having a sheet caliper is 430 pm to 500 pm.

45. The through-air drying fabric of claim 31, wherein the through-air drying fabric is configured to produce the tissue product having a stack caliper of ten sheets is above 4200 pm.

46. A method of forming a through-air dried tissue ply, the method comprising: providing a through-air drying fabric having a web contacting surface and comprising an additive manufactured, three-dimensional topography disposed on the web contacting surface, the three-dimensional topography defining a first shape and a second shape encompassed within and discontinuous from the first shape; forming an aqueous suspension of fibers; depositing the aqueous suspension of fibers onto a forming fabric to form a wet web; dewatering the wet web; transferring the dewatered wet web onto the web contacting surface of the through-air drying fabric; and through-air drying the dewatered wet web to form the through-air dried tissue ply, the through-air dried tissue ply including an imprinted three-dimensional topography imparted to the through-air dried tissue ply by the topography disposed on the web contacting surface of the through-air drying fabric, the three-dimensional topography defining a first design element corresponding to the first shape of the through-air drying fabric and a second design element corresponding to the second shape of the through-air drying fabric.

47. The method of claim 46, wherein the first design element defines a first enclosed area, wherein the second design element defines a second enclosed area; and wherein the second enclosed area is fully encompassed within the first enclosed area.

48. The method of claim 47, wherein the second enclosed area is fully encompassed within the first enclosed area.

49. The method of claim 46, wherein the first design element and the second design element are concentric.

50. The method of claim 46, wherein the first design element and the second design element are circular.51 . The method of claim 46, wherein the first design element and the second design element define segments that extend in a direction oblique to a machine-direction and oblique to a crossdirection.

52. The method of claim 46, wherein the first design element defines a first depth of impression, and wherein the second design element defines a second depth of impression that is the same as the first depth of impression.

53. The method of claim 46, wherein the first design element and the second design element define a set of design elements, and wherein the three-dimensional topography includes a plurality of sets of design elements.

54. The method of claim 53, wherein adjacent sets of design elements are staggered in a machine direction and in a cross -direction.

55. The method of claim 53, wherein the first design elements of adjacent sets of design elements intersect.

56. The method of claim 53, wherein adjacent sets of design elements are discontinuous.

57. The method of claim 53, wherein the plurality of sets of design elements are non-nesting.

58. The method of claim 46, wherein a geometric mean tensile of the through-air dried tissue ply is 950 g / 3” to 1200 g / 3”.

59. The method of claim 46, wherein a sheet caliper is 430 pm to 500 pm.

60. The method of claim 46, wherein a stack caliper of ten sheets is above 4200 pm.

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