| abstract |
A web (12) of highly bulked substrate is passed into a nip formed between a gravure roller (14) and an impression roller (15). The impression roller has raised areas defining an interconnected network of lines such that the web is compressed only under the raised areas; as a result, the binding liquid applied by the gravure roller (14) to the web is absorbed substantially through the web in the compressed areas. The gravure roller (14) may have a uniform surface, such that a light coating of binding liquid is applied to the surface of the uncompressed areas in the web, or the gravure roller may have a pattern of etched grooves or cells which matches and registers with the pattern of raised areas on the impression roller. In the latter embodiment, binding liquid will be absorbed into the web only in the compressed areas. The coated web (21) is applied to the surface (24) of a creping cylinder (25), is dried thereon, and is creped off with a creping blade (27) to form a product bound together by an interconnected network of lines of strength extending through the web. The areas between the lines of strength are not compressed and are not substantially coated with binding liquid, and thereby retain high bulk and absorbency. The once creped web may be passed through the identical process a second time such that the other side of the web receives binding liquid. The twice coated product still retains high bulk and absorbency in those areas which have not been compressed, and has lines of strength extending in a network through the product where the binding liquid has been applied. In a modified embodiment of the invention, a single impression/pressure roller with raised areas thereon is presses the web against a gravure roller and applies the web to a creping cylinder; and in a second modified embodiment, the web is pressed and coated on one side, is substantially hot air dried without compression, is coated with binding liquid applied to the other side, and is then applied to and creped from a creping cylinder. |