Multiple embossed flexible web

Claim 2

A web of nonwoven material comprising the combination of at least two layers of stretchable, soft cellulosic tissue and a fabric made of open-mesh threads interposed between the layers of cellulosic tissue and bonded thereto, said fabric including a first set of substantially parallel threads spaced from each other and extending in a first direction and a second set of substantially parallel threads spaced from each other and extending in a second direction so as to cross said first set of threads, any of said first and second sets of threads that extend in the longitudinal direction of said web being made of a resilient material, the composite material formed by said tissue and said fabric having been embossed under pressure repetitively by patterned embossing means to form embossments repeated continuously along the length thereof and superimposed on each other but out of register with each other with a substantial portion of the cellulosic tissue protruding beyond said threads to increase the bulk, yieldability and surface texture of the material, the cellulosic tissue having been permanently stretched by the embossing of the composite material without overstressing the threads.

Claim 3

A web of nonwoven material as set forth in claim 1 wherein the thread count of said threads is between about two and three threads per inch.

Claim 4

An improved nonwoven towel material comprising the combination of a central layer of fabric made of open-mesh crossed stretchable threads spaced from one another, at least one set of the threads being both stretchable and resilient, and a layer of stretchable, soft cellulosic tissue adhesively bonded to each of the opposite faces of said central layer of fabric, the composite material formed by said fabric layer and said cellulosic layers having been embossed under pressure repetitively by similarly patterned embossing means to form similar embossments repeated continuously along the length of the material and superimposed on but out of register with each other, the non-resilient cellulosic tissue and any non-resilient fabric threads having been permanently stretched by the embossing pressure without overstressing any given portion of the material including the threads, and the threads which are both resilient and stretchable having been temporarily distorted and allowed to spring back to substantially their original dimensions and configuration as the embossing pressure is released, so that a substantial portion of the cellulosic tissue protrudes through the windows of the open mesh fabric and beyond the opposite faces thereof to increase the bulk, yieldability and surface texture.

Claim 5

An improved nonwoven towel material comprising the combination of a central layer of fabric made of open-mesh crossed stretchable threads spaced from one another, at least one set of the threads being both stretchable and resilient, and a layer of stretchable, soft cellulosic tissue adhesively bonded to each of the opposite faces of said central layer of fabric, the composite material formed by said fabric layer and said cellulosic layers having been embossed under pressure repetitively by similarly patterned embossing means to form similar embossments repeated continuously along the length of the material and superimposed on but out of register with each other, the non-resilient cellulosic tissue and any non-resilient fabric threads having been permanently stretched by the embossing pressure without overstressing any given portion of the material including the threads, and the threads which are both resilient and stretchable having been temporarily distorted and allowed to spring back to substantially their original dimensions and configuration as the embossing pressure is released, so that a substantial portion of the cellulosic tissue protrudes through the windows of the open mesh fabric and beyond the opposite faces thereof to increase the bulk, yieldability and surface texture.

Claim 6

An improved nonwoven towel material comprising the combination of a central layer of fabric made of open-mesh crossed stretchable threads spaced from one another, at least one set of the threads being both stretchable and resilient, and a layer of stretchable, soft cellulosic tissue adhesively bonded to each of the opposite faces of said central layer of fabric, the composite material formed by said fabric layer and said cellulosic layers having been embossed under pressure repetitively at two or more stations spaced around a single rigid metal embossing roll wherein the material is pressed against said roll by a resilient roll to form similar embossments repeated continuously along the length of the material and superimposed on but out of register with each other, the non-resilient cellulosic tissue and any non-resilient fabric threads having been permanently stretched by the embossing pressure at each station without overstressing any given portion of the material including the threads, and the threads which are both resilient and stretchable having been temporarily distorted by the embossing pressure at each station and allowed to spring back to substantIally their original dimensions and congiguration as the embossing pressure is released, to increase the material bulk, yieldability and surface texture.

Claim 7

An improved nonwoven towel material comprising the combination of a central layer of fabric made of open-mesh crossed stretchable threads spaced from one another, at least one set of the threads being both stretchable and resilient, and a layer of stretchable, soft cellulosic tissue adhesively bonded to each of the opposite faces of said central layer of fabric, the composite material formed by said fabric layer and said cellulosic layers having been embossed under pressure repetitively at two or more stations spaced around a single rigid metal embossing roll wherein the material is pressed against said roll by a resilient roll to form similar embossments repeated continuously along the length of the material and superimposed on but out of register with each other, the non-resilient cellulosic tissue and any non-resilient fabric threads having been permanently stretched by the embossing pressure at each station without overstressing any given portion of the material including the threads, and the threads which are both resilient and stretchable having been temporarily distorted by the embossing pressure at each station and allowed to spring back to substantIally their original dimensions and congiguration as the embossing pressure is released, to increase the material bulk, yieldability and surface texture.

Claim 8

An improved nonwoven towel material comprising the combination of a central layer of fabric made of open-mesh crossed stretchable threads spaced from one another, at least one set of the threads being both stretchable and resilient, and a layer of stretchable, soft cellulosic tissue adhesively bonded to each of the opposite faces of said central layer of fabric, the composite material having been pressure embossed repetitively through the windows of the scrim with a similar embossment pattern to form similar embossments repeated continuously along the length of the material and superimposed on but out of register with each other, the non-resilient cellulosic tissue and any non-resilient fabric threads having been permanently stretched by the embossing pressure without overstressing any given portion of the material including the threads, and the threads which are both resilient and stretchable having been temporarily distorted by the embossing pressure and allowed to spring back to substantially their original dimensions and configuration as the embossing pressure is released, to increase the material bulk, yieldability and surface texture.

Claim 9

An improved nonwoven towel material comprising the combination of a central layer of fabric made of open-mesh crossed stretchable threads spaced from one another, at least one set of the threads being both stretchable and resilient, and a layer of stretchable, soft cellulosic tissue adhesively bonded to each of the opposite faces of said central layer of fabric, the composite material having been pressure embossed repetitively through the windows of the scrim with a similar embossment pattern to form similar embossments repeated continuously along the length of the material and superimposed on but out of register with each other, the non-resilient cellulosic tissue and any non-resilient fabric threads having been permanently stretched by the embossing pressure without overstressing any given portion of the material including the threads, and the threads which are both resilient and stretchable having been temporarily distorted by the embossing pressure and allowed to spring back to substantially their original dimensions and configuration as the embossing pressure is released, to increase the material bulk, yieldability and surface texture.