Multi-layer sheet material web assembly

An apparatus for making an embossed sheet material web assembly having a plurality of embossed layers of sheet material web crimped together, said apparatus comprising:

• a first roll comprising at least a first and second element extending radially therefrom, said first element having a greater radial height than said second element, said first roll having a first axis of rotation;
• a second roll having a second axis of rotation substantially parallel to said first axis of rotation, said second roll having a resilient surface forming a first nip with said first and second elements of said first roll;
• and
• a third roll having a third axis of rotation substantially parallel to said first and second axes of rotation, said third roll having a non-resilient surface forming a second nip with said first element of said first roll, said surface spaced apart from said second element of said first roll so as to avoid contact therewith;
• said plurality of layers of sheet material web disposed in said first nip between said first and second elements of said first roll and said resilient surface of said second roll and in said second nip between said said first element of said first roll and said non-resilient surface of said third roll, each layer of sheet material web comprising a plurality of embossments formed by said first and second elements at said first nip, wherein each of said plurality of embossments is raised in the same direction in each layer of said sheet material web and nests in the plurality of embossments raised in the other layers of said plurality of sheet material webs, said plurality of layers of sheet material web joined by crimps formed in said layers by said first element at said second nip.

A method for embossing and crimping a sheet material web assembly having a plurality of sheet material web layers, said method comprising:

• providing a plurality of layers of a sheet material web;
• providing a first roll having a first axis of rotation, said first roll comprising at least one element extending radially therefrom;
• providing a second roll having a second axis of rotation substantially parallel to said first axis of rotation and a resilient surface engaging said element so as to form a first nip therebetween as said first and second rolls rotate relative to each other so as to bring said element into engagement with said resilient surface;
• providing a third roll having a third axis of rotation substantially parallel to said first and second axis of rotation and a non-resilient surface engaging said element of said first roll so as to form a second nip therebetween as said first and third rolls rotate relative to each other so as to bring said element into engagement with said non-resilient surface;
• passing said plurality of layers of sheet material web through said first nip formed between said element of said first roll and said resilient surface of said second roll;
• forming an embossment in each of said layers of sheet material web by pressing said plurality of layers between said element of said first roll and said resilient surface of said second roll as said plurality of layers are passed through the first nip;
• passing said plurality of layers of sheet material web through said second nip formed between said element of said first roll and said non-resilient surface of said third roll;
• crimping said plurality of layers of sheet material web together by pressing said plurality of layers between said element of said first roll and said non-resilient surface of said third roll as said plurality of layers are passed through said second nip.