Abstract: A method of making a high gloss, multilayered thermoplastic film by pinning the extruding the molten thermoplastic film material onto a polished casting roll having a mirror finish. The thermoplastic film produced by this method has a superior gloss finish and has a ratio of distinctness of image in the machine direction to distinctness of image in the cross direction in the range of 1.3:1 to 1.0:1, and has a 20° gloss in the machine direction and the cross direction of at least 40.

Abstract: A calender for treatment of a web of a nonwoven textile V made of thermoplastic fibers. The calendar includes a heated embossing roller made of steel and a counter-roller that runs at the same circumference velocity. The local plastification in the nonwoven textile V that is produced at the locations of the raised embossing areas results in a board-like feel of the nonwoven textile V. To reduce this hardness, the web of the nonwoven textile V is broken, after having cooled at least partially.

Abstract: A method and work material for making embossed blanks for sample packages and other free-standing three dimensional display items from a sheet-type work material includes a printer for printing a graphic image on the work material, and a processing mechanism for performing work operations on the work material. The sheet-type work material has a top layer of sheet material, an intermediate layer of sheet material, and a carrier layer of sheet material, with a first layer of adhesive material bonding the top and intermediate layers of sheet material together, and a second layer of adhesive material bonding the intermediate and carrier layers of sheet material together. Any, all, or a combination of the top, intermediate, or carrier layers of sheet material may have shape retaining deformability characteristics to aid in holding an embossed design in the work material.

Abstract: The present invention relates to a process of forming a multi-layer pad of a non-woven fiber batt and a foam layer having conforming convoluted surfaces and to a multi-layer pad incorporating a non-woven fiber batt and foam layer. The process of forming a non-woven batt layer and a foam layer having conforming convoluted surfaces comprises transporting each layer along its longitudinal dimension while compressing each layer along its lateral dimension. Concomitantly with compression, each layer is cut transversely along its lateral dimension to separate each layer into an upper segment and a lower segment and to provide conforming convoluted surfaces on the segments of each layer, the convoluted surfaces comprised of upstanding projections and depressions.

Abstract: A method of utilizing a single engraved embossing roll to emboss different expanses of material with different patterns. The single engraved embossing roll has at least two projections projecting therefrom. A first of the projections projects to a greater height from the roll than a second of the projections. In another aspect, the invention encompasses an apparatus for embossing different expanses of material with different patterns. The apparatus includes an engraved surface having at least two projections projecting therefrom. A first of the projections projects to a greater height than a second of the projections. The apparatus also includes a backing surface configured to receive the projections of the engraved surface. The backing surface and engraved surface are together configured to receive an expanse of material between them.

Abstract: The invention relates to a flexible, waterproof shower pan liner comprised of a water-insoluble thermoplastic sheet. The shower pan liner includes on at least one surface selected indicia such as product information or plumbing codes at regular intervals. The indicia are embossed into the shower pan liner thereby eliminating the need for a protective top coat. In a process for making the invention, the thermoplastic is heated, calendered, and thereafter embossed with the selected indicia while in a heated condition.

Abstract: An interior automotive skin material has a thermoplastic resinous base coat/clear coat paint film bonded to the outer surface of a thermoplastically formable semi-rigid resinous backing sheet. The base coat/clear coat paint film is preferably formed by dry paint transfer techniques in which the clear coat layer and pigmented base coat layer are coated on a polyester carrier and dried, followed by transfer-laminating the base coat/clear coat paint film from the carrier to the backing sheet on which the clear coat layer forms a low gloss protective outer surface. The clear coat material preferably comprises an alloy of an acrylic resin and a fluoropolymer resin, preferably polyvinylidene fluoride. The low surface gloss of the outer clear coat is produced by a dispersed fine particulate filler such as silica combined with coating the outer clear coat layer on a matte carrier.

Abstract: A method of producing a flexible heat-exchange device including a body having a flexible mats and an internal passageway for heat-carrying fluid, an inlet and an outlet, including placing first and second plastic elastic mats in a mould die having supporting surfaces and recesses around the supporting surfaces, separating the first and second plastic elastic mats by a resilient counterdie, bringing the mould dies together with the first and second plastic elastic mats separated by the resilient counterdie into contact wherein the first and second plastic elastic mats are stretched down around abutment surfaces by deformation of the resilient counterdie and around the support surfaces and down into the recesses so as to obtain local plastic deformations as the mould dies are brought together, placing the second plastic elastic mat over the first plastic elastic mat, and mutually joining the first and second plastic elastic mats to form the body.

Abstract: The general application of the invention is a finishing process for an air-laid nonwoven web composed of short cellulosic fibers, bound by a thermoplastic binder and having a less than perfect homogeneous fiber distribution. In the invention, the process includes deforming under hot stress the web between an undeforming hard engraved cylinder and a slave cylinder having a hardness between about 60 and 90 degrees shore hardness D. The slave cylinder is resilient and deformable at the pressure applied to it by the engraved cylinder. In particular, the invention applies to the manufacture of webs and of disposable, decorative napkins.

Abstract: Lids, for example lids for machine-lidding of e.g. beakers, dishes, menu dishes, goblets, small packages etc., containing a substrate material featuring, with respect to a container on which the lids are used, a smooth outward facing surface bearing printing. On the inward facing side of the lid is a sealing layer deposited by extrusion laminate coating. The sealing layer exhibits on the free surface embossing with a depth of roughness of up to 50 &mgr;m. The embossing is transferred to the sealing layer in the form of a roughness pattern on the cooling roll on depositing the laminate coating of the substrate material and extruded sealing layer. The free side of the substrate material is smooth and exhibits no embossing. Printing on the free surface is therefore of higher quality. The extruded sealing layer on the substrate material exhibits embossing on the free side. If the lids are drawn from a stack of lids, for example in a filling machine, the embossing allows them to be separated individually.

Abstract: Polyolefin/filler breathable films may be produced by machine or transverse direction orientation using interdigitating grooved rollers. Biaxial orientation to similarly produce breathable films may be accomplished by the same method. By heating the rollers, the breathability of the film is increased without increasing the depth of engagement of the interdigitating rollers.

Abstract: Embossed textured films are made by feeding a thin thermoplastic polymer barrier film through the nip of a bonding roll assembly having a patterned roll and an anvil roll rotating at different circumferential speeds which differ by 5% to 200%. The bond pattern is imparted to the film as well as additional texture due to the differential speeds of the rollers thereby creating an embossed, textured barrier film having improved hand and a hydrohead in excess of about 30 mbar.

Abstract: The invention relates to a method and to an apparatus for perforating a web of material intended to form an outer casing sheet of absorbent articles. As the web is advanced, the web is first provided with a large number of mutually separated cuts in the nip defined between raised plateaus on a matrix cylinder and circumferentially extending knife-edges of a cutting cylinder. The web is then deformed transversely to its plane at parts which border on each cut. The invention also relates to a perforated outer casing sheet which includes recesses in the form of mutually adjacent elongated channel-like grooves.

Abstract: A method for embossing and crimping a plurality of sheet material web layers using an apparatus, including a first, second and third roll. The first roll including at least one element extending radially therefrom. The second roll has a resilient surface that engages the element to form a first nip therebetween. The third roll has a non-resilient surface that engages the element to form a second nip therebetween. In a preferred embodiment, the first roll includes at least a first and second element extending radially therefrom, with the first element having a greater radial height than the second element, which avoids contact with the third roll. The layers of sheet material web are embossed by the first and second elements as they are passed through the first nip, and are crimped together by the first element as they are passed through the second nip. In a preferred embodiment, the first roll includes a plurality of first and second elements arranged in a pattern.

Abstract: A method and apparatus for knurling a workpiece in which the knurl pattern includes grooves of at least two different configurations. The apparatus includes a knurl wheel holder that allows angular rotation of the knurl wheel about the holder longitudinal axis while maintaining the knurl wheel point of contact on the longitudinal axis. The apparatus also includes a knurling wheel that includes teeth of at least two different configurations. Also disclosed is a method of molding a molded article with the knurled workpiece to impart the inverse of the knurl pattern onto the molded article, such a molded article, a method of forming a structured abrasive article with the molded article, and such an abrasive article.

Abstract: An apparatus and methods for forming micro spike thermoplastic liners and micro spike thermoplastic liners formed thereby are provided. A textured thermoplastic liner having at least one roughened surface with a plurality of irregularly shaped projections extending therefrom is disclosed. The thermoplastic liner of the subject invention is formed by using a calendering roll having a generally cylindrically shaped body with a non-smooth outer surface and a plurality of blind apertures, each having an irregularly shaped opening formed coextensively with the non-smooth surface. The liner is formed by having the non-smooth surface of the calendering roll impress a roughened pattern onto the liner and simultaneously form the plurality of irregularly shaped projections. The calendering roll is formed by initially drilling a plurality of blind apertures and, subsequently, roughening the outer surface of the roll such that the openings of each of the apertures are each caused to be irregularly shaped.

Abstract: An improved method for texturing gypsum fiber panels and producing surface textured panels, edge tapers, and deeper patterned wainscot-type panels, involving the use of a flexible die with a textured surface. The die is pressed onto the panel in its slurry state just after the onset of an exothermic rehydration reaction. Partial hydration and setting occur during pressing by the die to form a textured mat. The mat is removed from contact with the die at a point along the rehydration temperature curve about at or less than one-half of the rise to the greatest rehydration temperature.

Abstract: An air filter suitably usable in an air cleaner, room air-conditioner or especially in car air-conditioners in which air is driven at a high speed. The air filter is made of a pleated polyurethane foam having on one or both sides thereof a three-dimensional network skeletal structure of micro cells.

Abstract: A cured tread making apparatus and method including a tread extruder from which a hot rubber compound continuously exits, a continuous rotational curing device comprising a heated rotatable drum and a cooperating moving tension belt adapted to provide continuous curing pressure against the rotating drum, and cast segments, incorporating a particular tread design, attached to the exterior circumferential surface area of the heated drum.

Abstract: A method for making a flexible, waterproof shower pan liner comprised of a water-insoluble thermoplastic sheet. The shower pan liner includes on at least one surface selected indicia such as product information or plumbing codes at regular intervals. The indicia are embossed into the shower pan liner thereby eliminating the need for a protective top coat. In the process for making the invention, the thermoplastic is heated, calendered, and thereafter embossed with the selected indicia while in a heated condition.

Abstract: An apparatus and method for printing and embossing elongated substrates provide for both length and position registration with respect to the printed and embossed patterns. The ink pattern to embossed pattern error is corrected by stretching or relaxing the substrate between the printing and embossing assemblies.

Abstract: A topsheet for body exudates absorbent article includes a hydrophilic nonwoven fibrous sheet and a plurality of thermoplastic synthetic resin filaments extending in one direction parallel to one another and continuously bonded to an upper surface of the nonwoven fibrous sheet so that a composite sheet of these sheet and filaments have crests and troughs alternately repeating longitudinally of the filaments and respectively extend transversely of the filaments. An apparatus and a method for manufcturing the topsheet are also disclosed, wherein a pair of mutually engageable embossing rolls are used for forming the crests and the troughs onto the coposite sheet.

Abstract: A process for preparing thermoplastics comprising the steps of cooling an extrudate to a temperature T1, drawing the molten extrudate, relaxing the extrudate at a temperature T3 for a duration of at least the average relaxation time of the thermoplastic at the relaxation temperature, and quenching the extrudate to a temperature T4. The process enables the manufacture of films consisting of at least one propylene homopolymer with a thickness of 100 to 250 &mgr;m and having a hot shrinkage of at most 20%, a haze of less than or equal to 3% and a total transparency with respect to air of greater than 70%.

Abstract: A method for shaping a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from one surface uses a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. At least a portion of the compressed material within the recesses is then cut from the surface of the slab by the blade just as the slab emerges from between the compression roller and the support surface.

Abstract: A process for producing a structured, voluminous nonwowen comprises the following steps: (a) a spun nonwoven is produced from a plurality of individual filaments which are stretched and gathered into a skein of fibers; (b) the skein is pressed and not-bonded into a crude nonwoven (12) through a first pair of rollers (9a, b); and (c) the crude nonwoven is further processed through a second pair of rollers (10a, b). The process is characterized in that the individual filaments are initially stretched merely up to a range from 50 to 70% of their maximum possible extension, and in that the crude nonwoven (12) is further processed through a pair of rollers (10a, b) composed of a positive roller (10a) with numerous nops or elevations (11) distributed over the outer surface of the roller and of a negative roller (10) with just as numerous recesses or depressions (12). During rolling, the nops engage the recesses and further stretch the crude non-woven in the area of the roller nops.

Abstract: A wood grain finish to a pultruded part is obtained by applying to a surface of the part before entering the die a strip carrying male projections shaped in differential depths and spacing across the width of the part to form a simulated wood grain pattern. The strip is then removed after the part is set leaving recesses in the outside surface which provide a simulated wood grain finish which can be differentially stained.

Abstract: An embossed metal foil laminate is prepared by laminating a metal foil to a paper web, utilizing an extrusion coated resin interlayer therebetween, by passing the layered structure between a nip roll and an engraved chill roll. The metal foil quickly conducts heat energy from the molten resin layer to the chill roll, allowing the process to be run at a high speed. The engraved chill roll impresses a pattern into the metal foil during the lamination operation.

Abstract: A method and system is provided for fabricating an elastomeric article, and comprises the steps of: providing a predetermined quantity of a comminuted rubber composition; heating the comminuted rubber composition to a predetermined processing temperature which effects at least a partial devulcanization thereof; forming a homogeneous dispersion by combining with that rubber composition a predetermined quantity of an additive composition; mixing with the homogeneous dispersion a predetermined quantity of a plastic composition and heating the resulting mixture to a predetermined extruding temperature to form a viscous compound composition; and, mechanically processing the viscous compound composition to form the elastomeric article.

Abstract: A process for producing strings for stringing rackets is provided. In accordance with various aspects of the invention, the surface of a string made of plastic is permanently deformed under pressure at normal temperature, it being the case that the surface profile is formed by depressions being impressed in the surface of the string.

Abstract: A simple, fast, and reliable method and apparatus are provided for replicating a light shaping surface structure on a laminated surface of a relatively rigid substrate. More specifically, after the substrate is mounted on a table and a layer of epoxy is deposited between the substrate and a submaster to produce a layered structure, the layered structure is automatically compressed in a nip formed between the table and an outer surface of a rotating impression roller, thereby replicating the surface structure in the epoxy layer. The epoxy is then cured, and the submaster is separated from the substrate to leave a laminated structure having the light shaping surface structure on a surface thereof. Preferably, the submaster is wrapped around the impression roller, and the impression roller is rotated while the table is reciprocated linearly to compress the layered structure in the nip.

Abstract: A flexible, open-pored cleaning body having at least one scouring surface (2) provided in at least one subregion with continuously formed, raised projecting ridges (3), wherein the ridges (3) have regions C,D of different heights in the direction of their extension.

Abstract: A method of making embossed optical polymer films and embossed optical polymer films made are described. The embossed optical polymer films have substantially the same optical properties as unembossed optical polymer films. The method includes providing an optical polymer film having first and second major surfaces, softening at least one of the first and second major surfaces to produce a softened surface, embossing the softened surface to produce an embossed optical polymer film, and cooling the embossed optical polymer film.

Abstract: A lenticular pattern forming roll, used for forming a lenticular screen, includes a chill roll and a lenticular sleeve positioned on the chill roll. The lenticular sleeve has a lenticular pattern formed on an outer surface for forming a corresponding lenticular pattern in a plastic sheet. The sleeve may be readily manufactured and transported to a desired location to be installed on the chill roll. The lenticular pattern forming roll may be readily used in combination with an extruder for extruding a hot plastic sheet to form the lenticular screen. The sleeve may also be removed from the chill roll and transported for resurfacing and without requiring transporting of the chill roll. The lenticular sleeve may preferably comprise a nickel-phosphorous composition defining at least a radially outermost portion of the sleeve in which the lenticular pattern is formed.

Abstract: A polishing roll, used for forming a smooth plastic sheet, includes a chill roll and a polishing sleeve positioned on the chill roll. The polishing sleeve has a polished outer surface for forming a corresponding smooth surface in a plastic sheet. The sleeve may be readily manufactured and transported to a desired location to be installed on the chill roll. The polishing roll may be readily used in combination with an extruder for extruding a hot plastic sheet to form the smooth plastic sheet. The sleeve may also be removed from the chill roll and transported for resurfacing and without requiring transporting of the chill roll. The sleeve may preferably comprise a nickel-phosphorous composition defining at least a radially outermost portion of the sleeve in which the polished surface is formed.

Abstract: A device for increasing the hardness and intensity of wood which comprises chuck means for holding the wood in a fixed position for processing, a compression-shaped forming die for compressing the wood being processed, an ultrasonic wave-generating device operatively connected with the compression-shaped forming die for applying sound waves to the wood, a forming mold positioned downstream of said compression-shaped forming die for receiving wood therefrom, said forming mold further compressing said wood to remove a portion of the water contained therein, and means for advancing the chuck means containing the wood being processed through the compression-shaped forming die, the ultrasonic wave-generating device and the forming mold.

Abstract: The general application of the invention is a finishing process for an air-laid nonwoven web composed of short cellulosic fibers, bound by a thermoplastic binder and having a less than perfect homogeneous fiber distribution. In the invention, the process includes deforming under hot stress the web between an undeforming hard engraved cylinder and a slave cylinder having a hardness between about 60 and 90 degrees shore hardness D. The slave cylinder is resilient and deformable at the pressure applied to it by the engraved cylinder. In particular, the invention applies to the manufacture of webs and of disposable, decorative napkins.

Abstract: A topsheet for body exudates absorbent article includes a hydrophilic nonwoven fibrous sheet and a plurality of thermoplastic synthetic resin filaments extending in one direction parallel to one another and continuously bonded to an upper surface of the nonwoven fibrous sheet so that a composite sheet of these sheet and filaments have crests and troughs alternately repeating longitudinally of the filaments and respectively extend transversely of the filaments. An apparatus and a method for manufcturing the topsheet are also disclosed, wherein a pair of mutually engageable embossing rolls are used for forming the crests and the troughs onto the coposite sheet.

Abstract: Cellulosic webs can be embossed using an extended nip structure with embossing means in a controlled nip dwell zone. Single and multiply wipes and towels produced by plying together two or more such webs can be embossed. Webs having common caliper and basis weight can be processed using the extended nip structure with an appropriate embossing means. The tendency of the embossed relief to relax and disappear after processing can be substantially alleviated by controlling dwell time to ensure reliable embossing.

Abstract: The present invention relates to a method of forming ornamented plastics articles and to articles formed by the method and relates especially but not exclusively to manufacture of items of furniture, building components and picture frame members. The method comprises firstly extruding a plastics article then re-moulding it in a hot stamp press. This enables highly complex forms of article to be manufactured with large dimensions and at much lower cost than is currently possible.

Abstract: An endless belt composed of a shape memory alloy is used for surface finishing thermoplastic film or sheet as it leaves the die of an extruder, or finishing roll of a calender or some means to heat the surface of the film or sheet to the required softening temperature. Since shape memory alloys have the unique property of increasing in volume as they get colder, instead of decreasing in volume, the tendency of the film or sheet to stick to the endless belt is decreased. This allows for the continuous production of surface finished film or sheet.

Abstract: An apparatus and method for thermally forming a surgical suture tip from a length of unfinished surgical suture material having a varying cross-section. The thermally formed surgical suture tip has a generally uniform cross-section along its length, and the varying cross-section corresponds to a distribution of different cross-sectional sizes along the length of the unfinished surgical suture material. A first heating die has a first face with a first groove therein for receiving a portion of the length of the unfinished surgical suture material, and a second heating die has a second face with a second groove therein. The first and second grooves extend along a common axis. At least one mechanical actuator is provided for moving the first face of the first heating die against the second face of the second heating die and for contacting the first and second grooves against an outer surface of the unfinished surgical suture material.

Abstract: A method for treating a roller cover includes the steps of positioning an element with respect to a roller cover and removing a portion of the roller cover with said element to form a pattern on said roller cover. The process for treating roller covers for a paint roller may also includes the steps of providing a surface, forming a pattern on the surface, heating the surface, and contacting the roller cover with the heated surface. The heated surface is a metal. The heat is transferred from the heated metal surface to the roller cover when the heated metal surface contacts the roller cover. The heated surface sears or melts the nap of the roller cover. The surface can be provided with a pattern so that a pattern can be placed into the nap of the roller cover. An apparatus used to treat the surface of a roller cover includes a surface having a desired pattern therein. A holder for a roller cover holds or presents the roller cover to the surface. A heater is attached to the surface.

Abstract: A method of embossing thermoplastic sheet by continuously advancing thermoplastic sheet through an embossing nip defined by a rotating embossing roll with an engraved surface at elevated embossing temperature and an opposite fixed rigid concave member and pneumatically forcing the sheet against the engraved surface while within and continuously passing through the nip.

Abstract: Provided is a method for manufacturing a thermoplastic resin sheet bearing an embossed pattern, which employs a manufacturing apparatus having a first roll having an elastic material coated surface, a mirror-faced metal, endless belt, which is wound around the first roll and a second roll, and a third roll so provided that the metal, endless belt is wrapped partially around the third roll, which contacts the first roll via the metal, endless belt and which has an embossed pattern formed on one surface. According to this method, the thermoplastic resin sheet, partially melted, is fed between the metal, endless belt, which contacts the first roll, and the third roll. The elastic member is elastically deformed by application of a pressing force between the first and the third roll, while face pressure welding the thermoplastic sheet by using the first and the third rolls to transfer the embossed pattern and to cool the thermoplastic resin sheet. A surface temperature for the third roll of from 0.degree. C.

Abstract: Absorbent articles containing absorbent cores of fluff pulp frequently contain wrinkles in the absorbent core that run from side to side of the article, typically normal to the machine direction in the manufacturing process. Side-to-side wrinkles are deleterious in that they provide large flow channels for urine or other body fluids to escape to the edge of the article. Frequently, such wrinkles are present after manufacturing, before the article has been folded or worn. The cause of the wrinkles is believed to be due to natural instabilities during compression of the fluff pad shortly after it is formed. Means for reducing cross-directional wrinkles include the use of grooved, drilled, or patterned compression rolls to densify the fluff pulp while providing opportunities for reduced in-plane displacement during compression or, if in-plane displacement does occur, providing paths for cross-directional displacement as well as machine-direction displacement so that continuous CD wrinkles cannot form.

Abstract: This invention provides a method for continuously forming an array of optical elements which includes feeding synthetic resin sheeting having a temperature in the flow temperature region of the synthetic resin directly to a thermoforming zone of embossing means; continuously pressing the sheeting against a mold provided on the embossing means and having a pattern for defining an array of optical elements while maintaining the sheeting at that flow temperature, to bring the sheeting into intimate contact with the mold and thereby form an array of optical elements on one surface of the sheeting; laminating a surfacing film to the side of the sheeting opposite to the mold as required; feeding a carrier film to the side of the resulting laminate opposite to the mold and bringing the carrier film into close contact therewith; and cooling the sheeting to a temperature lower than the glass transition temperature of the synthetic resin, as well as apparatus therefor.

Abstract: The present invention provides a method and apparatus for impressing a diffraction image into an oriented polymeric film wherein, after orientation of the film, the temperature of the film is raised to a desired annealing temperature, the film temperature being continuously maintained above room temperature while a diffraction pattern is embossed directly into the surface of the film.

Abstract: The present invention provides a stable nonwoven web having enhanced extensibility and a method for making the same. A neckable nonwoven web is fed in a first direction. The neckable nonwoven web is subjected to incremental stretching in a direction perpendicular to the first direction. A tensioning force is applied to the neckable nonwoven web to neck the nonwoven web. The necked nonwoven web is then subjected to mechanical stabilization to provide a stabilized extensible necked nonwoven web. The stabilized extensible necked nonwoven web is easily extended in a direction parallel to the direction necking.

Abstract: Disclosed is a device for forming a hinge in a sheet of extruded plastic. Plastic material is extruded and passed between a pair of rolls to determine the thickness of the plastic sheet. A groove forming member of a scoring assembly then creates a groove in the sheet of plastic when the plastic is still warm. The groove forming process creates a plastic ridge on both sides of the groove. To flatten these ridges, the sheet then passes through a second set of rolls. The sheet of plastic, still warm, is then cooled by a conventional method. The scoring assembly is movable along the width of the sheet of plastic and is adjustable for the depth of groove. The scoring assembly can also be removable. Once a groove is created, the groove acts as a hinge and the sheet can be bent or folded along the grooved edge.

Abstract: High sheet count rolls of spot-embossed, soft bathroom tissue suffer from embossing patterns becoming pressed out by the high winding tension necessary to confine the size of the roll to a diameter of about 5 inches. This size is necessary in order for such high sheet count rolls to fit within the bathroom tissue dispensers found in most households. However, by embossing the tissue between a resilient back-up roll and an engraved embossing roll having short male embossing element heights of only from about 0.005 to about 0.035 inch, the tissue sheet becomes simultaneously calendered, which lowers the sheet caliper (as measured under a compressive load). Because of the resulting lower caliper, the embossed sheet can be wound into the required roll size with less tension on the sheet, such that the embossing pattern for tissue sheets within the roll remains well defined.