CN100460173C - 热粘合穿孔无纺布 - Google Patents

热粘合穿孔无纺布 Download PDF

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CN100460173C
CN100460173C CNB038168014A CN03816801A CN100460173C CN 100460173 C CN100460173 C CN 100460173C CN B038168014 A CNB038168014 A CN B038168014A CN 03816801 A CN03816801 A CN 03816801A CN 100460173 C CN100460173 C CN 100460173C
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nonwoven
perforation
embossed
roller
perforated
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CN1668427A (zh
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马蒂亚斯·穆特
阿克塞尔·里希特
拉尔夫·佐德曼
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Corovin GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
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Abstract

本发明涉及制备穿孔无纺布材料1的方法，其中带有轧花点的预粘合的无纺布14导入无纺布穿孔设备5，针辊6上的针8在预粘合的无纺布上穿孔。该穿孔无纺布材料1然后进行进一步加工。针的数目与轧花点数目之间的比值设定在0.15-0.25之间，孔的尺寸与轧花点尺寸之间的比值设定在0.15-0.25之间。

Description

热粘合穿孔无纺布
技术领域
本发明涉及制备穿孔无纺布的方法以及穿孔无纺布。还提供实施该方法和/或制备该无纺布所用的无纺布穿孔设备。
背景技术
给材料穿孔，如果其目的是为给材料提供特殊性能，例如，给予对液体和/或气体的渗透性能，则其是现有技术的一部分。例如，在美国专利US 3,965,906中，提供穿孔的卫生制品的顶层。为了该目的，可以使用针辊，其沿直径对置于刷式辊。用该穿孔设备可以对薄膜或无纺布穿孔。无纺布或薄膜当作为卫生用品的顶层使用时，将会吸收液体并将其导入卫生用品的内部。穿孔设备从欧洲专利申请EP1046479A1以及欧洲申请专利EP 1048419中已知一种穿孔设备，其具有一个针辊和一个带孔的辊。无纺材料和薄膜可通过针辊和带孔辊之间并穿孔。使用该装置还特别可以完成三维穿孔。
WO 9967454公开一种由纤维制造带有遍布无纺布横截面的穿孔结构的无纺布材料的方法。穿孔结构通过以下步骤而制成，将纤维铺在筛网带上形成纤维网，随后在穿孔机构上穿刺该纤维网，并将它在粘合单元中转变为无纺布。为此，穿刺机构包括两个元件。一个元件具有许多指向纤维网的长钉。第二元件具有开口，第一元件的长钉部分伸入该开口中，并在纤维网通过时对纤维网的纤维无损伤地移动，从而形成孔眼结构。第二元件的这些开口连接到过压和真空源上，能够将处于开口区域的纤维吸入或吹出所述开口。由此生产的无纺布的孔眼结构直径为0.5mm至5mm，并且每平方厘米有40至120个粘合点，而且粘合表面占无纺布材料表面的10％至40％。这导致孔眼尺寸与粘合点尺寸间的比率>0.76。
WO0034562描述了一种生产结构化、蓬松无纺布网或膜的方法和装置。在此方法中，按照该文献图2的未结构化纤网前进通过一对辊，其含有带遍布辊套表面周围许多凸起物的主动辊(10a)，和一个被动辊(10b)，其有许多类似的孔洞。在滚压过程中，主动辊的凸起物啮合这些孔洞并在辊啮合的区域中拉伸这种未结构化的网，使得产生有许多孔腔的深拉网结构。随后，仍然粘附在主动辊上的网与一个对辊接触，该对辊也提供孔洞，纤网被主动辊在对辊上穿孔。
EP1046479A1和EP1048419A1中公开了将一平面结构穿孔并变形的方法。为此，包括许多针的刺针元件和带有许多接收刺针的孔眼的橡胶或金属(权利要求7)配对元件的一种设备被用于在平面结构中以受控的方式形成各自的穿孔边缘。按照这些文献的权利要求16，每个刺针在穿孔和变形区域中啮合到配对元件的孔眼中，从而，平面材料被穿孔。按照权利要求17，平面结构在提高的温度下穿孔和变形。在此情形下，穿孔和变形区域中的一致性由辊温度和变形元件温度起决定性作用。权利要求6和12公开了可调节刺针的穿刺深度。
EP 0214608A2描述了穿孔无纺布网的方法。该方法使用安装了许多刺针的一个主动辊，它与配对辊接触。无纺布被穿刺，以至穿孔刺针进入对辊的空穴中，并从而穿孔该无纺布网。
发明内容
本发明的目的是可以连续穿刺形成大致圆形的孔。
为实现这一目的，本发明提供一种生产穿孔无纺布的方法，具有权利要求5所述特征的穿孔无纺布，具有权利要求6所述特征的穿孔无纺布，和具有权利要求7所述特征的无纺布穿孔设备。更有利的实施方案和特征在所附权利要求书中规定。
本发明提供穿孔无纺布的生产方法，将一种具有轧花点的预粘合、特别是热粘合的无纺布引导到无纺布穿孔设备中。无纺布穿孔设备的针辊上的刺针啮合到无纺布中并穿刺无纺布。接着进一步加工该无纺布。这可在无纺布穿孔设备后直接进行或以后再进行。例如，该无纺布穿孔后，使用重绕装置卷绕。无纺布的表面也可以是受处理的。例如，可以在无纺布的表面涂覆一种或多种物质。本发明提出，使针辊上刺针数目与所提供的带轧花点无纺布上的轧花点数目之比设定在0.15-0.25之间，并且将穿孔无纺布上的孔眼尺寸与热粘合无纺布上的轧花点尺寸之比设定至少为4。如果孔眼数与轧花点数之比在0.15-0.19之间，则可获得进一步的改善。已经表明，如果相应的穿孔装置与无纺布上的轧花点彼此相关地设计，则有利地是在穿孔无纺布上得到尽可能圆的孔。否则，所得的穿孔会有凹口或可能是椭圆形。特别是，对于预定的轧花表面，已经显示，用相应数目的小轧花图形而不是用少量但尺寸相当大的轧花生产这种轧花表面会更有优越性。试验表明，在穿孔步骤中，小的轧花图形比大轧花图形更容易移动。以下，轧花点的概念将被理解为落入上述定义的所有轧花图形。根据一个实施方案，这些轧花图形无中间间隔地覆盖整个表面。根据另一个实施方案，这些轧花图形至少部分提供了中间间隔，例如为环形。此外，轧花图形可以是圆形、长菱形、椭圆形、矩形和/或近似星形。也可以一起使用不同的轧花图形。
可以从下表中得知进行不同试验所用的试验辊参数。使用的辊为刻花辊。然而轧花图形也可以例如采用电火花腐蚀(spark erosion)或其它制造方法雕刻在基体上。基体并非必须绝对是辊，除了辊，也可以采用条带或其它类似物。
 
辊 顶视所见的图形形状   施压区的尺寸(mm)     施压面积(mm<sup>2</sup>)    图形数目(个/cm<sup>2</sup>) 施压面积比(％)      
辊1 圆形 0.541 0.208 69.86 14.49
辊2 圆形 0.756 0.449 32.65 14.66
辊3 椭圆形 0.834<sup>＊</sup>0.495   0.325 49.90 16.19
试验显示，如果轧花图形的施压区介于0.15mm2-0.4mm2之间，优选在0.18mm2-0.35mm2之间，则会是有利的。轧花图形的数目会介于43-80个/cm2之间。辊上施压区的比例优选例如为10％-18％。
所用无纺布上的轧花点数在55个/cm2-80个/cm2之间是有利的。可由开卷机提供适当热处理的无纺布。另一个实施方案提出，直接从无纺布生产设备引导无纺布到一台热粘合设备。然后把具有需要的轧花点数和轧花尺寸的热粘合无纺布导入无纺布穿孔设备中。在无纺布中优选产生10个孔/cm2-20个孔/cm2。特别在卫生应用领域，已经表明，如此的孔数目有利于无纺布吸收遇到的液体。对于卫生方面的应用，穿孔无纺布，例如用作顶层。进一步的应用领域是家庭领域例如抹布的表层，医务部门用来做盖布，例如防护服，以及其它领域。而且，这种无纺布还可用于过滤用品、建筑材料和/或与其它材料的层状结构，这些可以是织物、用金属或热塑性材料做成的膜，甚至可以是刚性表面、纸、纸板，或者甚至是网。
在示例实验中使用的针辊的尺寸列于下表。
 
辊 顶视图中的刺针形状       刺针直径[mm]     刺针面积[mm<sup>2</sup>]    刺针数[根数/cm<sup>2</sup>] 刺针面积比[％]      
针辊 圆形 1.95 2.987 15.36 45.86
针的嵌入深度优选在2mm-4.5mm之间，特别优选例如，在2.5mm-3mm。例如针的嵌入深度特别是无纺布厚度的函数。优选，在卫生领域中，使用重量在14gsm-50gsm之间的无纺布。在其它领域中，无纺布的重量可超过50gsm，特别在建筑行业作为纺织品和作为土工布。
无纺布的优选孔尺寸在0.8mm2-1.8mm2之间。而且，带有因热粘合而产生的轧花点的穿孔无纺布，其穿孔数与轧花点数之比在0.15-0.25之间，并且孔眼尺寸与轧花点尺寸之比设定为至少为4。如果穿孔数与轧花点数之比在0.15-0.19之间，则可获得额外的改善。
下表复制了穿孔无纺布的示范性数据。这套数据从单位面积重量为30gsm的单层纺粘无纺布上得出。
 
孔尺寸 面积(mm<sup>2</sup>) 1.16
直径MD(mm) 1.33
直径CD(mm) 1.11
轴比MD/CD 1.2
开口面积 (％) 18.7
厚度 (mm) 0.709
抗张强度 MD(n/50mm) 26.63
CD(N/50mm) 23.52
伸长率 破裂时，MD(％) 21.93
破裂时，CD(％) 30.14
MD：纵向； CD：横向
不同的变量会影响不同的强度性能。这些变量可以是孔数、无纺布上的轧花点数目、它们的尺寸以及其它参数。
这些参数优选经设定使得无纺布在MD方向的强度大于CD方向的强度。特别是，无纺布的最小强度在CD方向为6N/50mm，在MD方向的强度为8N/50mm。特别在卫生应用中，如果无纺布例如作为顶层，则优选在两个方向上的强度均至少为20N/50mm。
所用的无纺布可以是单层的或多层的。它可以有一种聚合物或多种聚合物。可用的聚合物特别是：聚丙烯、聚乙烯、聚酰胺、聚酯等。无纺布可以是纺粘无纺布、熔喷无纺布、短纤维无纺布或其它不同的材料。无纺布的纤维可以是多组分纤维。
根据本发明另一个构思，穿孔无纺布上的轧花点是通过热粘合制备的，在无纺布上的穿孔有弹坑似的边缘，其在无纺布上突起。无纺布上轧花点的最长轴小于无纺布上穿孔的穿孔边缘的高度。特别是，考虑孔的边缘位于轧花点旁，轧花点的最长轴与孔边缘的高度为一定比例。可以看出，选择这种类型的三维尺寸和孔之间的比例以及无纺布的热粘合，可以观察到极大均匀性的圆孔，其可以连续生产。
本发明的另一个构思提出，提供实施上述方法和/或制备上述无纺布所用的无纺布穿孔设备。该无纺布穿孔设备有至少一个针辊和一个配对辊。针辊与配对辊之间形成间隙。无纺布导入该间隙中穿孔。针辊上的刺针数为10-25针/cm2，至少一些刺针具有圆形直径。有效的刺针直径为1.5-2.5mm。针辊表面上刺针占的面积比例为35-65％之间，有效的刺针直径是接触无纺布时用于产生穿孔并决定它们大小的直径。
优选特征和实施方案源自以下附图。并非按照其中所显示的特征限制本发明，而是可与上述本发明的实施方案组合成进一步的独立细化设计，它们在这里未进行更详细的描述。
附图说明
图1 显示第一穿孔无纺布，
图2 显示穿孔的特写示图，
图3 显示无纺布穿孔设备的示意图。
具体实施方式
图1显示穿孔无纺布1的一个例子。无纺布是单层，单位面积重量为30gsm。无纺布是纺粘无纺布，其根据Dokan方法制备。标准聚丙烯用作热塑性材料。这里无纺布以俯视图形式图示，黑背景作为铺底。而且，该图显示尺寸为mm。这里使用的放大系数1.5。除了可看作为黑孔的穿孔2，还有轧花点3。轧花点3比穿孔2小得多。孔2优选至少是轧花点3的4倍大。
图2显示放大的图1。图解说明了穿孔无纺布1，其具有穿孔2和周围的轧花点3。可以看出无纺布1的纤维通过穿孔过程而被移动，并形成孔边缘4。优选维持该纤维此情形下的结构。纤维未被熔融。另外一个实施方案提出，把纤维加热到软化温度，使得相邻的纤维在其表面上彼此粘合。轧花点3也被部分包含在孔边缘4。尽管这些轧花点导致无纺布一定的刚度和强度，但是轧花点的尺寸最好被设计成能导致孔为近似圆形。如果轧花点的尺寸与穿孔2尺寸相比太大，形成的孔眼就有形成凹口的危险。不采用圆形孔2，而是产生椭圆形孔和其它形状的孔也是可以的。已经证明，如果轧花点的长轴小于孔边缘4的高度，则特别有利。该高度在穿孔过程中由于无纺布的变形而产生。不同的是，较结实的轧花点通过无纺布的变形而变形，使得穿孔的边缘生产锯齿形。
图3显示有一个针辊6和配对辊7的无纺布穿孔设备5。针辊6上有刺针8。刺针8啮合进入配对辊7的表面9中，表面9优选受到刺针8作用而变形。特别是，表面9可以有毡类材料。而且，无纺布穿孔设备5具有开卷装置10。预粘合无纺布14，其具有轧花点，通过多个辊12导入开卷装置10到达配对辊7。辊12上优选具有张力测量辊13。张力测量辊能检测作用在将被穿刺的无纺布14上的张力。可例如通过辊12并经张力测量辊13来设定该张力，特别是与配对辊7与开卷装置10相互配合作用。从张力测量辊13，准备穿孔的无纺布14被引导到配对辊7，并围绕其上特定的范围。此范围优选大于45度。在该范围内可以，例如加热无纺布。特别是，可将无纺布加热到低于所用聚合物或生产无纺布聚合物的熔融温度的温度。另外，该无纺布也可以加热到热塑性材料软化温度。从配对辊7，准备穿孔的无纺布14被引导至间隙15。间隙15用针辊6和配对辊7形成。在间隙15中，要被穿刺的无纺布14用刺针8穿孔。这种情况下，刺针8与配对辊7的表面9啮合。按照无纺布穿孔设备5的实施方案，该要穿孔的无纺布优选从配对辊7导入到针辊6。无纺布优选在针辊6上保持某一包角范围。整个包角范围优选大于45度，特别是该范围在90度-270度之间。将穿孔后的无纺布1保持在针辊6上特别有利于稳定孔的边缘。取代将穿孔无纺布绕在针辊6上，而是将该穿孔无纺布也可以在间隙15后被引导到一卷绕机16上也是可以的。辊12优选再次设置在针辊6和卷绕机16之间。辊12之一优选是张力测量辊13。来自针辊6的穿孔无纺布1可以用这种方式以可调的确定张力再次卷绕在卷绕机16上。

Claims (4)

1.生产穿孔无纺布材料(1)的方法，其中带有轧花点(3)的预粘合无纺布(14)导入无纺布穿孔设备(5)，针辊(6)上的刺针(8)啮合到预粘合的无纺布(14)上并穿刺它，然后，对该穿了孔材料(1)进一步加工，
其特征在于，
针的数目与轧花点的数目之比设定在0.15-0.25之间，孔眼尺寸与轧花点尺寸之间的比值至少为4，轧花图形的施压区介于0.15mm2-0.4mm2之间，制备的无纺布(14)的孔尺寸在0.8mm2-1.8mm2之间。
2.根据权利要求1的方法，其特征在于，无纺布(14)通过数量在55点/cm2-80点/cm2之间的轧花点进行热粘合。
3.根据权利要求1或2的方法，其特征在于，在无纺布(14)上产生的穿孔数在10孔/cm2-25孔/cm2之间。
4.穿孔无纺布材料(1)，其具有热粘合产生的轧花点(3)，其特征在于，该无纺布材料的穿孔数与轧花点的数目之比在0.15-0.25之间，孔眼尺寸与轧花点尺寸之间的比值至少为4，轧花图形的施压区介于0.15mm2-0.4mm2之间，从而制备的无纺布的孔尺寸在0.8mm2-1.8mm2之间。
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US20050217091A1 (en) 2005-10-06
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US7386924B2 (en) 2008-06-17
US20070124902A1 (en) 2007-06-07
US7192392B2 (en) 2007-03-20
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