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CA1289713C - Method and apparatus for producing variable patterns and bonded areas - Google Patents

Method and apparatus for producing variable patterns and bonded areas

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Publication number
CA1289713C
CA1289713C CA000503951A CA503951A CA1289713C CA 1289713 C CA1289713 C CA 1289713C CA 000503951 A CA000503951 A CA 000503951A CA 503951 A CA503951 A CA 503951A CA 1289713 C CA1289713 C CA 1289713C
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Canada
Prior art keywords
calender rolls
pattern
web
rolls
register
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
CA000503951A
Other languages
French (fr)
Inventor
Gary H. Meitner
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Kimberly Clark Corp
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Kimberly Clark Corp
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Abstract

ABSTRACT OF THE DISCLOSURE
A method of and apparatus for changing the pattern impressed in or on a web of material passing through the nip of opposing calender rolls is disclosed.
A plurality of calender rolls are provided with a pat-tern of lands and grooves. While a web of material is passed through the nip or nips formed at least in part by each patterned roll, the relative register between the patterned rolls is maintained so that the pattern created by the overlap of each pattern impressed on the web continues in an unchanging fashion throughout the length of the web thus processed. By altering the rela-tive register of the patterned rolls, and then maintain-ing the rolls in the new register, a distinctive compos-ite pattern is impressed in or on the web without other-wise altering the patterned calender rolls.

Description

~2~ 3 , M~THOD AND APPARATUS FOR PRODUCING VARI~8LE
PATTER*~S A~TD BO~ED AREAS
BACKGROUND OF T~E INVENTION
This invention relates to methods of and appar~-tus for producing patterns in or on a web or webs of material using calender rolls. More particularly, _his inventi~n relates to methods of and apparatus for produc-ing variable parterns. One use of this invention is to produce variable bond patterns in th-rmoplastic webs.
In many instances it is desirable to produce a pattern on a web of material, and to have different patterns available for different end uses of the ma-terial. For example, in producing non-woven fabric containing either thermoplastic fibers or a thermoplas-tic bonding material, webs o the material are passed through heated calender rolls. The pattern of lands and grooves on the rolls is impressed on the web, and contact with the lands of the patterned calendar roll produces thermal bonding between the fibers in the mater-ial.
The ?attern of the thermal bonding is impor-~ant i.n severai aspects. Eirst, the extent of bonding effects the strength and integrit~y of the resulting fabric. Second, ~he bonding affects other characteris-tics, such as the feel of the resulting web or its suit-ability for its intended use.

~8~7~3 Third, the bond pat'ern itsslf, if distinctive, may serve a useful purpose in identifying the material, or products made from it.
One method of obtaining different bonding patterns is to use different calender rolls for eac;~
desired bond pattern. Several references have disclosed combinations of patterns that produce different bond patterns when used on opposing calende- rolls. For example, U.S. ~atent No. 3,507,943 discloses four sets of calender rolls formed with helically shaped lands and the resulting patterns produced using those sets of calender rolls. Likewise U.S. Patent Nos 4,005,i69 and 4,008,726 disclose various calender roll patterns and resulting bond patterns. Because it is not easy to maintain the register between opposing calender rolls, the particular patterns disclosed in these patents were designed so that when the rQgister between the calender rolls changes, the varia~ions caused ~y the changes will not be no~iceable in the produce~ pat~erns.
The use of multiple calender rolls for form-ing a variety of bond patterns has several drawbacks.
Most importantly, the cost of producing and maintaining an inventory of calender roll patterns is quite ex~
pensive. For example, in a typical operation using ~4 inch diameter rolls, one engraved pa~terned roll cost in the thousands of dollars.
- Another disadvantage is that unless separate calender stacks are maintained for each pattern to be produced, there is considerable time and expensive in-volved in changing rolls used in a stack.

SUMMARY 0~ THE INVENmION

The present invention is directed to a method of and apparatus or obtaining a variety of distinct ~%~7~3 patterns using a small number of patterned calender rolls The web o~ material is passed through the nip or nips ~ormed by a plurality or patterned calender rolls, and the pattern or each roll is reproduced in overlapping rorm in or on the web. The relative register of the calender rolls is main-tained so that the resulting pattern remains substantially unchanged. When a dirrerent pattern is desired, however, t'ne register o~ the patterned calender rolls is altered. The resulting pattern formed by the overlapping o~ the patterns on the rolls in a di~erent relative position i5 di5tinct from the first pattern rormed in or on the web.
Tne pattern may be changed between webs, or during the processing o~ a single web.
~ y using suitable patterns and maintaining the register during operation, but altering the register between pattern chan~es, a small number o~ pa~terned rolls, even just two, can produce many distinct patterns, though each pattern is unchanging throuyhout its production. In this manner many patterns can be produced without the cost or maintaining a large inventory o~ patterned calender rolls and the time and expense of changing rolls within a calender stac~.
More specirically, the inven~ion resides in maintaining the relative register of the patterned calender roll so that a first pattern is impressed in or on the web or webs or material, tne ~irst patten repeating itself without appreci-able variation, and then changing the relative register either circumferentially or by movement in the direction o~
an axis, or in both ways by adjustin~ one or both or the patterned calender rolls and maintaining the new register to produce a second repeated pattern in tne web or webs of material, the second pattern di~rering appreciably ~rom the rirst pattern.
One aspect o~ tne invention resides in an apparatus ror creating a variety of patterns in or on a web or webs o~
material, the apparatu~ including a plurality o~ calender rolls, at least two of which are patterned and rorm a nip with an opposing calender roll. The apparatus has means ~or maintaining the relative register o~ the pattern calender rolls and means ror changing the relative register o~ the ., .

~2~39J-~ ~

pattern calender rolls with means for then maintaining tne new relative register.
The invention itself, together with further advantages, will best be understood by reference to the following detailed description and the accompanying drawings.

~ 3 Q

~2~97~

BRIEF DESCRIPTION OF THE DRAWI~IGS
FIGURE 1 is a schematic representation of an apparatus useful for practicing one preferred em~odimsnt of the presen inventior FIG-~RE 2 represents a pattern of lands ~nd grooves suitable for use in the em~odiment of the present invention associated with FIGURE 1.
FIGURES 2a-2i represent the -~ariety of dis-tinct patterns tnat can be formed using the pattern of EIGURE 2.
FIGURE 3 represents another pattern of lands and grooves suitable for use in the embodiment of 'he present invention associated with FIGURE 1.
FIGURES 3a 3d represent the variety of dis-tinct patterns that can be formed using the pattern of FIGURE 3. -~
FIGURE 4 is a schematic representation of an apparatus useful for practicing another preferred embodi-ment of the presen. invention.
FIGURE 5 represents a pat~ern of l~nds and grooves suitable for use in the embodiment of the present invention assoclated with FIGURE 4.
FIGURES 5a-5e represent the variety of dis-tinct patterns that can be formed using the pattern of FIGURE 5.
FIGURE 6 is a perspective schematic view of the apparatus of FIGURE l.
FIGURE 7 is a schematic diagram of the method ^teps of the present invention. ., DETAILED DSCRIPTION OF THE D~AWINGS .~ND PREFERRED
EMBODIMENTS

Figure 1 represents a first preferred embodiment of the present invention. The ap~a-atus o~ Figure 1 comprises ~ stack of calerder rolls, particularly includ-ing c~lender rclls 10, 20 an~ 30, each rotating i~ the direction shown b~ r~spe~tive ~rr~ws 1~, ~2 a~d 32.

7~3 , Engraved on calender rolls 10 and 30 is a pattern of lands and grooves. The patlerns may both be t:ne same or may be different. ror purpose of illustration, ~
invention will be described in terms of bond area pat-terns produced by heated calender rolls wherein bothrolls 10 and 30 have a pattern like that of Figure 2 engraved on their surface.
Passing be~ween ~he r.ips ;S and ZS formed res~pectfully by caiender rolls lO and 20 and b-~ rolls 20 and 30 is a web of material 40, moving in the direc-tion shown by arrow 42. The calender roll 20 acts as a back-up, anvil or opposing calender roll. At nip 15, the web of material 40 first contacts the lands of calende- roll 10. In so doing, the pattern of roll 10 is pressed into the material 40. Due to the heated nature of the calender rolls, the fibers of we'o 40 con-tacting the lands of roll 10 are fused together. The resul~ing bond pat~ern created in we_ ~0 thus stays in the web as it undergoes further processing.
As the web of material 40 passes through the nip 25 between calender rolls 20 and 30, the pattern of the lands on roll 30 is lil~ewise pressed into the web 40. Depending on the relative register of the rolls 10 and 30, and the patterns on rolls 10 and 30, the lands of roll 30 may contact areas of web 40 already bonded, or previously unbonded areas which then becomes bonded.
It is the combination of the patterns on rolls 10 and 30 which produces the ultimate pattern of bonds in web 40. Figure 2a shows one resulting bond pattern created by the apparatus of Figure 1 when both rolls 10 and 30 have ~he pa.tern of rigure 2 engraved ~hereon.
In order for the pattern OI 2a to be contin-uously repeated as rolls 10, 20 and 30 rotate, the rela-tive register of rolls 10 an~ 30 must be maintained quite closely. As used hereir, ~he term reiative regis-ter refers to the respective positions of the patter..edrolls via impressions made on the web of materiaL 40.
Thus, even though rolls 10 and 30 do not cor,~act one another, they are in relative register when a repeated impression in web 40 made by a iand on roll 10 suc-e3-sively contacts the same point on roll 30 as the weD 40 continuously moves through the nips 15 and 25.
Maintaining the register O r the rolls during produc~ion is essential to pra_ticing the present in-vention. The degree of precision reguired is a func-tion of the size of the lands and grooves making up the patteirn. When the size of the lands and grooves are small, a shift in the relative register will be evident as the patterns of rolls 10 and 30 will no ionger over-lap in the same manner. For example, with the ~atte.nof Figure 2, a change in the register of about 1~16 inch would maXe a subs~antlal dif erence in the pattern produced. Therefore the calender rc ls 10 and 30 must be maintained in axial register wi~h a precision of at least .02 inches. For the same .02 lnch precision on the circumference of a 24 inch diameter roll, the cir-cumferential register must also be maintained to within o ~ 1 o ~
As depicted in Fi~ure 7, the invention is practiced by maintaining the relative register of the patterned rolls 10 and 30 until suffi-ient guantities of material 40 have been processed with one desired pattern, then altering the relative register and main-taining the new relative register while ?rocessing addi-tional material ~0. The register may be changed ineitner of two directions, or both di~ections at the same time. For exampie, roll 10 or 3C could be moved in a hori70ntal direction (parallel to its axis of rota-tion). Alternatively, roll 10 or 30 could be rotated in its circum~erential direction. Or both rol~s could 97~3 , be shifted at the same time. ~.ny combination of norizon-tal and circum.^erential moves of one or ooth rolls i3 and 30 could be made, so long as the resulting over;ap of tXe patterns impressed on the web 40 b,v the two ~oi~s is different 'han the overlap of the _2~ terns before the change o relative register is made. Web 40 may be the same wQb to which the first pattern was applied, or a dif'erent web of material.
, Fïgure 2b shows another pattern created D~ a diferent overlap of the same pattern used to make the pattern of Figure 2a. A comparisGn of the patterns in Eigures 2a and 2b gives an indication of the wide variance in bonding patterns that may be created with only two calender rolls, each using the same pattern.
lS Likewise Figures 2c - 2i depict patterns that may also be created using the same engraved calender rolls as would be used to make the patterns of Figures 2a and 23.
Another example of the variety of pat'erns that may be created using only two patterned calender rolls is depicted in Figures 3a - 3d, which may be made from the apparatus depicted in Figure l wherein both rolLs lO and 30 are engraved with the pattern of Figure 3.
Since the same side of web 40 cortacts both rolls lO and 30, impressions made by both rolls are on the same side of the web 40. In low basis weight mater-; ials where it is not obvious whether bonding is one-sid-ed, the configuration of Fig. l is suitable. Howe-~er, in higher basis weight materials in whlch it is apparent which side the bonding is formed from, it may be desir-able to have bonding formed from both sides of the web.
Figure 4 depicts a second preferred embodimen~
of the present invention which produces bonding forme~
from bsth sides of the web.

The apparatus of Figure 4 ig essen'ially tre same as that ln Figure 1 except that there is no anS~il roll and both patterned rolls 110 and 130 act as the back-up or opposing rolls for one ano her. As rolls 110 and 130 rotate in the dlrection of arrows 112 and 132 re~pectlvely, the web of material 140 passes throu~h the nip 125 between them in the direction shown by arrow 142.
. In some instances, especially in bonding low basis weight webs, it may be necessary to shim the calen-der rolls 110 and 130 so that hydraullc loading of the rolls does not resuit ln metai-to me~al contact and premature wear of the pattern.
As the web 140 passes through nip 45, both sides of web 140 are contacted by lands rom the pat- ~
terns on rolls 110 and 130. In this second embodiment, however, only those portions of the web 140 that are contacted simultaneously on both sices by lands from the opposing rolls wili result in ~c-ded areas. (In the embodiment of Figure 1 the anvil roll 20 provided continuous backup, and bond areas are formed at each point of contact between a land and the web 40.) There-fore, the resulting bond area is comprised of the inter-ference pattern created by the overlap of patterns on rolls 110 and 130. In addition, the bonds of web 140 are formed by lands compressing fibers on both side of the web, rather than on the same side as results from the apparatus of Figure 1.
The embodiment of Figure 4 otherwise works identically like the embodiment c. Flgu.e ' The rela-tive register of rolls 110 and 130 lS main~alned through-out a production run so that the pattern is unchanging.
When a new pattern is desired, the relative regis er of ~9713 -the roll~ 110 and 130 is altered by shifting or.e or both rolls in either a horizontal or -ircumferentiai direction.
An example of a pattern usefui with t..e em-bodiment of Figure 4 ia shown in Figu~e S. ~he pat ernof bonds created by the interferen~Q of the lands of two rolls 110 and 130 each engraved with the patte_n of Figure 5 is depic~ed in ~igures Sa - Se. Each OL tne patterns of Figures ;a - 5e is a variation created Dy altering the relative register between rolls 110 and 130.
The bonds depicted in Figure 5a are formed with the "waves" of the calender roll patterns in phase. The wavy pattern of Figure 5a can range from a very thick to a very thin bond by adjusting the amount of overlap of the bonds while keeping the "waves" in phase.
Figure 6 illustrates the camponents of an apparatus for practicing the invent:o~ corresponding to the embodiment of Figure 4. Besides the patterned calender rolls 110 and 130 and means for driving them, the apparatus includes circumferential and axial register adjustment means. The adjustment means cooperate with the calender rolls 110 and 130 to provide means for maintaining the relative register of the patterned rolls, means for changing the relative register, and means for then maintaining the new relative register. In most cases, the means for maintaining tne original and altered relative register are the same pieces of equipment. mhe apparatus of Figure 6 may include conventional roll heating apparatus if the rolls are to be used for thermal bonding.
Means for maintaining and changing the rela-tive register of the rolls include well known _g_ , ~2~37~

mechanical or electrical systems. An example of a mechanical system includes calender rolls geared together, ~ith the gear on one roll being fastened to the roll with a connection that may be slipped. To change the circumferential register, the gears rsmain stationary, the connection is loosened, tno roll is rotated, slipping in rslation to the gear, and the con-nection is tightened. Chan~es in horlzontal register arç made by having the rolls positioned in a bearing wi~h a system for sliding the axle axially in the bear-ing then holding it in position. An example of an elec-trical system includes calender rolls driven by electric motors using well known digital process control to main-tain or change the relative circumferential register.
With the present invention it is possible to quickly and inexpensively create a variety of patterns from a small number of patterned calender rolls. Also, without changing the patterns used, _he degree of bond-ing can be easlly adjusted by chang ng the amount by which the bonds formed by one pattern overlap with the bonds formed by the other pattern.
The present invention has been described using two patterned rolls, but any number of rolls greater than two could also be used, in which case the ultimate pattern on the web would be a composite of the patterns formed in the web as it passed through each nip formed, at least in part, by a patterned calender roll. The apparatus of Figure 1 is particulary well adapted for use , of more than two calender rolls. The a?paratus of ~igure 4 could also be used with more than one pair of pat_erned rolls. I' more than two patterned rolls were used with either embodiment, however, the register of all patterned rolls relative to one another would need to be maintained during a production run of a particular pattern.

~J~

--1 .
Also, while the present i~ entior. r.as Deen described in rela'ion to its use for forming variable bond patterns in webs of thermoplastic fibe~s, t could be used in any instance in which pat~err.ed caler.der rolls are used to impart a design to a web of mate~ial, such as printing wrapping paper, wai'paper and the like, embossina ?aper, applying pattsrn3 o plastic films, displacing fibers i~ non-woven mate~ial, etc.
The invention is also suitable ~or producing patterns when bonding a plurality of webs together.
The in~ention is particularly suitable for bonding spunbonded fabrics, meltblown 'abrics, fabrics made from meltblown microfioers blended with synthe~ic or natural fibers such a di~ellicated wood fibers and laminates of any of the abo~e, either with themse'-~es, with one another or with thermoplastic films. Examples o some of the abo~e materials and the methods of pro-ducing and embossing them are given ~ n, U. S. Patents No.
4,426,417 to Meitner et al., 4,100,3- to Anderson et al., 4,041,203 to Brock et al. and 3,978,185 to Buntin et al.
The temperature, pressure, pattern, roll mater-ial, web thickness, and nip speed suitable for bonding, embossing or printing will vary depending on the web material used in practicing the invention. However, the process parameters will be the same as for conven-tional methods of bonding, embossing or printing the particular web, and are well known in the ar~.
A wide -~Jarie~y of products -an be made form webs of materlal treated as desc-ibed :nerein. For example, some of the preferred materlals i-.ciude ~i?ss, tent fabrics, absorbent garment back ng material and other products made from textured spunbonded materials.
~ther products include paper towels and textured polymer sheets.

~9~3 Of course i~ shouid be understood ';hat a wide variety of changes and modifications will be apparent to those skilled in ths art. For example, the rel~ti-re register of the two rolls of the firsr preferre~ embodi-ment could be altered in a circumferential direction b~changing the distance the web 40 travels ~etween ~he two nips 15 and Z5, such as by passing the web 40 over an idler roller after it passes through nip 15 and De-fo~e it passes through ni? 25. In that nstance as the distance between the nips 15 and 25 and the idler roller is varied, the rela'ive register between rolls 10 and : 30 would change, without the actual register of the rolls changing.
It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limitlng, and tha' the following claims, inc'uding all equivalents, are intended to define the scope of the invention.

Claims (26)

1. A method of producing different patterns in or on a web or webs of material passing through the nip or nips of opposing calender rolls comprising the steps of:
(a) providing a plurality of calender rolls with a pattern of lands and grooves, (b) passing a web or webs of material through a nip formed between each of said patterned calender rolls and an opposing calender roll;
(c) maintaining the relative register of said pat-terned calender rolls so that a first pattern is impressed in or on the web or webs of material, said first pattern repeating itself without appreciable variation; and (d) changing the relative register of said patterned calender rolls and then maintaining the new register to produce a second unchanging pattern in the web or webs of material, said second pattern differing appreciably from said first pattern
2. The method of claim 1 wherein the plurality of pat-terned calender rolls comprises two patterned calender rolls.
3. The method of claim 2 wherein the two patterned calender rolls act as the opposing calender rolls for each other, forming a nip between them, and the web or webs of material is or are passed through the nip thus formed.
4. The method of claim 3 wherein the patterns and the relative register of the two patterned calender rolls are such that the opposing lands of each pattern do not reach the nip simultaneously and the pattern impressed on the material is comprised of an interfer-ence pattern created by the overlap of the patterns on the two patterned calender rolls.
5. The method of Claim 2 wherein each patterned calender roll forms a nip with a common opposing anvil calender roll, and the web or webs of material is or are passed through both nips thus formed.
6. The method of Claim 2 wherein the patterns of each patterned calender roll are substantially identical.
7. The method of Claim 1 wherein the patterned calender rolls are heated.
8. The method of Claim 1 wherein the web or webs of material comprises a web of spunbonded material and the pattern impressed thereon comprises a bonding pattern.
9. The method of Claim 1 wherein the web or webs of material comprises meltblown microfibers blended with synthetic or natural fibers.
10. The method of Claim 1 wherein the web or webs of material comprises laminates of spunbonded, meltblown or thermoplastic webs and the pattern impressed thereon is a bonding pattern.
11. A method of changing the pattern impressed in or on a web or webs of material passing through the nip or nips of opposing calender rolls comprising the steps of:
(a) maintaining a plurality of calender rolls, each with a pattern of lands and grooves and each forming a nip with an opposing calender roll, in a register relative to the other patterned calender rolls such that the pattern im-pressed in or on a web or webs of material passing through the nip or nips formed by each of said patterned calender rolls repeats itself in an unchanging fashion and (b) changing the relative register of the patterned calender rolls and maintaining the new register to change the pattern transferred to the web or webs or material to a new unchanging pattern.
12. The method of Claim 11 whereby the relative register of the patterned calender rolls is changed by shifting one or more of the patterned calender rolls in a direction parallel with the axis of rotation of that roll.
13. The method of Claim 11 whereby the relative register or the patterned calender rolls is changed by rotating one or more of the patterned calender rolls in a circumferential direction.
14. A method of using only two patterned calender rolls to provide a variety of bond patterns in thermoplastic webs compris-ing the steps of:
(a) continuously passing a thermoplastic web through the one or more nips formed at least in part by the two patterned calender rolls;
(b) maintaining the relative register of the two patterned calender rolls sufficient to yield a substantially unchanging bond pattern in said thermoplastic web; and (c) altering the relative register of the two pat-terned calender rolls and then maintaining the new relative register sufficient to yield a distinct and substantially unchanging bond pattern in said thermoplastic web or a different web.
15. The method of Claim 14 further comprising the steps of:
(a) stopping the passage of the thermoplastic web through the one or more nips formed by the two patterned calender roils while the relative register of the rolls is altered and then (b) continuously passing additional thermoplastic web through the one or more nips formed by the two patterned calender rolls.
16. A method of printing different patterns on a web of material passing between the nips of opposing calender rolls comprising the steps of:
(a) maintaining a plurality of calender rolls, each with a pattern suitable for printing and each forming a nip with an opposing calender roll, in a register relative to the other patterned calender rolls such that the pattern printed on a web of material passing through the nips formed by each of said patterned calender rolls repeats itself in an unchanging fashion and (b) changing the relative register of the pat-terned calender rolls to a new register and maintaining the new register to change the pattern printed on the web of material to a new unchanging pattern.
17. An apparatus for creating a variety of patterns in or on a web or webs of material comprising;
(a) a plurality of calender rolls, at least two of which are patterned and form a nip with an opposing calender roll;
(b) means for maintaining the relative register of the patterned calender rolls; and (c) means for changing the relative register of the patterned calender rolls; and (d) means for then maintaining the new relative register.
18. The apparatus of Claim 17 wherein the at least two calender rolls comprise two engraved calender rolls.
19. The apparatus o Claim 18 wherein the two engraved calender rolls form a common nip.
20. The apparatus of Claim 18 wherein the two engraved calender roils form a nip with a common calender roll.
21. The apparatus of Claim 17 wherein the means for maintaining and the means for changing the relative register comprise gears mounted on said calender rolls with at least one gear rotationally slidably connected to the calender roll on which it is mounted and means for preventing and allowing rotational sliding between said at least one gear and said calender roll on which it is mounted.
22. The apparatus of Claim 17 wherein the means for maintaining and the means for changing the relative register comprises at least one calender roll mounted in bearing mounting means which include axially slid-able connecting means and means for preventing and allo-ing axial sliding between the at least one calender roll and its bearing mounting means.
23. A method of producing different patterns in or on a web or webs of material passing through the nip or nips of opposing calender rolls comprising the steps of:
(a) providing a plurality of calender rolls with a pattern of lands and grooves, said plurality of rolls formed such that they are capable of interacting to produce a variety of treatment patterns by movement in the direction of an axis and by adjustment of the circumferential register of said rolls;
(b) passing a web or webs of material through a nip formed between each of said patterned calender rolls and an opposing calender roll;
(c) maintaining the relative register of said pat-terned calender rolls so that a first pattern is impressed in or on the web or webs or material, said first pattern repeating itself without appreciable variation; and (d) changing the relative register either circum-ferentially or by relative shifting said rolls in a direction parallel with the axes of rotation thereof, or in both ways by adjusting one or both or said patterned calender rolls to produce a second pattern in the web or webs of material and maintaining the new register, said second pattern repeating itself and differing appreciably from said first pattern.
24. A method of changing the pattern impressed in or on a web or webs or material passing through the nip or nips of opposing calender rolls comprising the steps of:
(a) maintaining a plurality of calender rolls, each with a pattern of lands and grooves and each forming a nip with an opposing calender roll, said calender rolls formed such that they are capable of interacting to produce a variety of treatment patterns by adjustment by movement in the direction of an axis and by adjustment of the circum-ferential register of said rolls, in a register relative to the other patterned calender rolls such that the pattern impressed in or on a web or webs of material passing through the nip or nips formed by each of said patterned calender rolls repeats itself in an unchanging fashion; and (b) changing the relative register of the pat-terned calender rolls either circumferentially or by relative shifting said rolls in a direction parallel with the axes of rotation thereof, or in both ways by adjusting one or both of the rolls, and maintaining the new register to produce a second repeated pattern transferred to the web or webs of material.
25. A method of using only two patterned calender rolls to provide a variety or bond patterns in thermoplastic webs comprising the steps of:
(a) continuously passing a thermoplastic web through the one or more nips formed at least in part by two heated patterned calender rolls;
(b) maintaining the relative register of the two patterned calender rolls sufficient to yield a substantially unchanging bond pattern in said thermoplastic web and (c) altering the relative register of one or both of the two patterned calender rolls in a direction parallel with the axis of rotation of the respective roll, in a circumferential direction, or in both directions and then maintaining the new relative register sufficient to yield a distinct and substantially unchanging bond pattern in said thermoplastic web or a different thermoplastic web.
26. An apparatus for creating a variety of patterns in or on a web or webs of material comprising:
(a) a plurality of calender rolls, at least two of which are patterned and form a nip with an opposing calender roll wherein said calender rolls are formed such that their relative register may be changed circumferentially or in a direction parallel with the axes or rotation of the calender rolls or in both directions to create a variety of patterns on material passed through such rolls;
(b) means for maintaining the relative register or the patterned calender rolls; and (c) means for changing the relative register of the patterned calender rolls; and (d) means for then maintaining the new relative register.
CA000503951A 1985-04-15 1986-03-12 Method and apparatus for producing variable patterns and bonded areas Expired - Lifetime CA1289713C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US72341385A 1985-04-15 1985-04-15
US723,413 1985-04-15

Publications (1)

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CA1289713C true CA1289713C (en) 1991-10-01

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014044235A1 (en) * 2012-09-21 2014-03-27 Pegas Nonwovens S.R.O. Nonwoven webs with enhanced softness and process for forming such webs

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014044235A1 (en) * 2012-09-21 2014-03-27 Pegas Nonwovens S.R.O. Nonwoven webs with enhanced softness and process for forming such webs

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