(57) An apparatus for embossing a fibrous web includes a mated pair of resilient and rigid
embossing rolls 50,54 wherein the resilient roll 54 is formed e.g. by laser burning,
with recesses 56 adapted to receive protuberances 52 on the rigid male embossing roll
50 when the rolls are placed in contact. By providing recesses on the resilient roll,
the pressure or force required for causing the resilient material, e.g. rubber, to
flow around the protuberances can be significantly decreased as compared to conventional
rubber to steel embossing. As a result, wear on the rolls is reduced, and smaller
diameter rolls may be utilized, thereby reducing the cost of the embossing equipment.
In addition, since less pressure is required to cause the rubber to flow about the
protuberances, roll deflection is not a problem, and an embossed pattern can be imparted
having a consistent, high degree of definition across the width of a web.
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