Method and device for producing an embossed web material and product made in this way

A method for producing an embossed sheet material including at least two layers of web material joined together, comprising steps of:

• embossing a first layer of web material, previously provided with a background pattern made up of a first set of protuberances, so as to generate on the first layer a second set of protuberances, which are partially superimposed on the first set of protuberances making up the background pattern, and defining an ornamental motif made up of a pattern of major dimensions and minor density with respect to the background pattern,
• embossing a second layer of web material for generating thereon a third set of protuberances having the same density as the protuberances of said second set,
• coupling by means of adhesive to said first layer of web material at least said second layer of web material,
• wherein the adhesive is applied to a top surface of at least some protuberances of said third set of protuberances, the sheet material being substantially free of adhesive in correspondence with protuberances of said first set of protuberances forming said background pattern,
• wherein protuberances of said second set and said third set are inserted inside one another,
• wherein said first set of protuberances and said second set of protuberances are generated on the first layer by running said first layer around a first pressure roller interacting with a first embossing cylinder and a second embossing cylinder that have respectively a first set of points and a second set of points, the second set of points being of larger dimension and lower density than the first set of points, and
• wherein said second layer is run around said first pressure roller, downstream of an area in which the first layer is embossed between said first embossing cylinder and said first pressure roller, and embossing said second layer on said first layer between the first pressure roller and the second embossing cylinder.

A method for producing an embossed sheet material including at least two layers of web material joined together, comprising steps of:

• embossing a first layer of web material, previously provided with a background pattern made up of a first set of protuberances, so as to generate on the first layer a second set of protuberances, which are higher than and partially superimposed on the first set of protuberances making up the background pattern, and defining an ornamental motif made up of a pattern of major dimensions and minor density with respect to the background pattern, said first set of protuberances and said second set of protuberances protruding from a common face of said first layer;
• and
• coupling by means of adhesive to said first layer of web material at least a second layer or web material,
• wherein the adhesive is applied in areas corresponding to at least some protuberances of said second set of protuberances, the sheet material being substantially free of adhesive in correspondence with protuberances of said first set of protuberances forming said background pattern,
• wherein said second layer of web material is provided with a background pattern made up of a set of protuberances,
• wherein said first layer and said second layer are separately embossed by corresponding first and second embossing units, which generate protuberances forming the background pattern on the first layer and the second layer, and are then run around a first embossing cylinder provided with points for generating said ornamental motif on the first layer and for joining the first layer and the second layer,
• wherein said first layer is embossed according to said background pattern between a pair of rollers of a first embossing unit and is subsequently embossed on said first embossing cylinder provided with points for generating said ornamental motif, and
• wherein the second layer is embossed between a second embossing cylinder and a pressure roller of said second embossing unit, said second embossing cylinder being provided with points for generating said background pattern on the second layer and wherein the first layer and the second layer are joined between said first embossing cylinder and said second embossing cylinder.

A method for producing an embossed sheet material including at least two layers of web material joined together, comprising steps of:

• embossing a first layer of web material, previously provided with a background pattern made up of a first set of protuberances, so as to generate on the first layer a second set of protuberances, which are partially superimposed on the first set of protuberances making up the background pattern, and defining an ornamental motif made up of a pattern of major dimensions and minor density with respect to the background pattern, wherein the background pattern on the first layer of web material is provided by embossing in-line and before the embossing of the first layer for generating said ornamental motif,
• coupling by means of adhesive to said first layer of web material at least a second layer of web material, wherein the adhesive is applied in areas corresponding to at least some protuberances of said second set of protuberances, the sheet material being substantially free of adhesive in correspondence with protuberances of said first set of protuberances forming said background pattern,
• generating said first set of protuberances and said second set of protuberances on the first layer by running said first layer around a first pressure roller interacting with a first embossing cylinder and a second embossing cylinder that have respectively a first set of points and a second set of points, the second set of points being of larger dimension and lower density than the first set of points, and
• joining together said first layer and said second layer between the first pressure roller and the second embossing cylinder that interacts with the first pressure roller.

A method for producing an embossed sheet material including at least two layers of web material joined together, comprising steps of:

• embossing a first layer of web material, previously provided with a background pattern made up of a first set of protuberances, so as to generate on the first layer a second set of protuberances, which are partially superimposed on the first set of protuberances making up the background pattern, and defining an ornamental motif made up of a pattern of major dimensions and minor density with respect to the background pattern, wherein the background pattern on the first layer of web material is provided by embossing in-line and before the embossing of the first layer for generating said ornamental motif,
• coupling by means of adhesive to said first layer of web material at least a second layer of web material, wherein the adhesive is applied in areas corresponding to at least some protuberances of said second set of protuberances, the sheet material being substantially free of adhesive in correspondence with protuberances of said first set of protuberances forming said background pattern,
• generating said first set of protuberances and said second set of protuberances on the first layer by running said first layer around a first pressure roller interacting with a first embossing cylinder and a second embossing cylinder that have respectively a first set of points and a second set of points, the second set of points being of larger dimension and lower density than the first set of points, and
• running said second layer around said first pressure roller, downstream of an area in which the first layer is embossed between said first embossing cylinder and said first pressure roller, and embossing said second layer on said first layer between the first pressure roller and the second embossing cylinder.

A method for producing an embossed sheet material including at least two layers of web material joined together, comprising steps of:

• embossing a first layer of web material, previously provided with a background pattern made up of a first set of protuberances, so as to generate on the first layer a second set of protuberances, which are partially superimposed on the first set of protuberances making up the background pattern, and defining an ornamental motif made up of a pattern of major dimension and minor density with respect to the background pattern,
• coupling by means of adhesive to said first layer of web material at least a second layer of web material,
• wherein the adhesive is applied in areas corresponding to at least some protuberances of said second set of protuberances, the sheet material being substantially free of adhesive in correspondence with protuberances of said first set of protuberances forming said background pattern,
• wherein said second layer of web material is provided with a background pattern made up of the set of protuberances,
• wherein said first layer and said second layer are separately embossed by corresponding first and second embossing units, which generate protuberances forming the background pattern on the first layer and the second layer, and are then run around a first embossing cylinder provided with points for generating said ornamental motif on the first layer and for joining the first layer and the second layer, and
• wherein said first layer is embossed according to said background pattern between a pair of rollers of a first embossing unit and is subsequently embossed on said first embossing cylinder provided with points for generating said ornamental motif, and wherein the second layer is embossed between a second embossing cylinder and a pressure roller of said second embossing unit, said second embossing cylinder being provided with points for generating said background pattern on the second layer and wherein the first layer and the second layer are joined between said first embossing cylinder and said second embossing cylinder.