Texture subtractive patterning

Abstract

The present application provides a method of manufacturing a patterned tissue product comprising a textured background surface, and a design element wherein the design element is formed by removing a portion of the textured background. The method comprises the steps of (a) providing a tissue web having a textured top surface lying in a surface plane and a bottom surface lying in a bottom plane wherein there is a z-directional height difference between the surface plane and the bottom plane; (b) conveying the web through a first nip created by a first receiving roll and a pattern roll having a plurality of protuberances forming a design pattern; (c) conforming a portion of the web to the protuberances; and (d) conveying the web into a second nip formed between the pattern roll and a second receiving roll to form a patterned tissue product having a design element corresponding to the plurality of protuberances, the design element lying in a design element plane that is between the surface plane and the bottom plane. The textured surface provides the tissue with an overall background pattern that is typically visually distinct from the design element imparted thereon. The method may further comprise the step of applying a papermaking additive or water to the conformed portion of the web via an applicator roll between step (c) and (d). The pattern roll is generally a hard and non-deformable roll, such as a steel roll. The first receiving roll has a hardness greater than 40 Shore (A), such as from 40 to 100 Shore (A). The second receiving roll may have a smooth or non-smooth surface, and the pressure applied at the second nip is greater than 30 pli, such as from about 50-250 pli.