Multilevel embossing of sheet materials

Claim 1

A process for embossing a web of material wherein said material is composed of a composite structure having a carrier, a non-foamed embossable wear layer and a foamed layer therebetween, said foamed layer on the surface thereof adjacent the wear layer having a decorative pattern printed thereon, said above composite structure being in the form of a web which is heated to a temperature of about 225° F. to 350° F., the process comprising: (a) embossing the embossable wear layer of the web with a first shallow embossing means which embosses a surface texture of about 5 mils to a substantial portion of the embossable wear layer including areas to be further embossed and particularly including areas which will not be subsequently embossed. (b) deeply embossing in a pattern the embossable wear layer of the web with a "bottomless" embossing means to emboss deeply to about 15 mils a portion of the web to form depressed area therein while, at the same time, not contacting or embossing the raised areas of the web between the depressed areas of the web, (c) carrying out the step of deep embossing without destroying at the point of deep embossing the surface texturing which was previously applied by the first embossing step, and (d) laterally guiding the web to the embossing means so as to provide a registry of the embossed pattern with the printed pattern in a direction transverse to the direction of web movement.