CN101500790A - Wave-like structures bonded to flat surfaces in unitized composites and methods for making same - Google Patents

Abstract

A simplified manufacturing technique to directly form a unitized composite structure with at least one relatively flat surface and at least one sinuous element in an internally-bonded unitized composite is provided. A matrix of fibrous and or other materials is deposited in layers which are subsequently formed into corrugated or wave-like shapes and exposed to an activation step. At least one element is composed of a contractive material which shrinks when activated, such as by heating in an oven, to become relatively flat and optionally bonded to at least one other non-contractive layer which remains in a sinuous shape after the activation step.

Description

Be adhered to the wavy structure and the manufacture method thereof of flat surfaces in the synthetic complex

The application advocates to be called in the name of application on June 14th, 2006 the U.S. Provisional Patent Application case No.60/813 of " WAVE-LIKE STRUCTURES BONDED TO FLATSURFACES IN UNITIZED COMPOSITES AND METHODS FORMAKING SAME (being adhered to the wavy structure and the manufacture method thereof of flat surfaces in the synthetic complex) " according to 35U.S.C § 119 (e), 433 priority, its full content is incorporated this paper into by quoting.

Technical field

The present invention relates to a kind of manufacture method with synthetic compound fabric structure of at least one sinusoidal linear element of being attached to each other and at least one relatively flat element.

Background technology

Usually relative level and smooth, the surfacing of non-woven fabric, film, textile, paper and the paper board material of making, density are even, and compare thin with its length and width.When needs have at least one smooth flanks than thick structure the time, usually use known wrinkling and stacked processing technology that the web-like product material of the web-like product material of at least one relatively flat and the relatively flat that at least one is other is made up and bonding, wrinkling one-tenth sine of the latter or wave shape also are adhered on the material of relatively flat with some adhesives usually.

The result of this lamination produces following combination adhesive stacks structure: its with not wrinkling at the web-like product, compare with the situation of its initial even shape combination when being bonded together relative thicker and have a lower global density.In addition; the lamination of---being adhered on one or more flat support parts---provide additional advantage often can also for synthetic laminated construction to make up one or more corrugated elements, and these advantages comprise compressibility, overall structure rigidity, load support ability, buffer capacity, insulating properties and various other structure of for example controllable z direction and have the raw-material function benefit of rationally effectively using.

At the general corrugated fibre box of carrying and be widely used between the storage life protection product is an exemplary example that is generally used for setting up lamination and creping.The bonded combination body at least one corrugated, sinusoidal shape or wavy layer and at least one relatively flat surface makes that the global density of combining structure is low, and has for example following desired function character, as rigidity control, the rigidity of structure and load support intensity, and has the smooth outer surface that is suitable for printing with the expectation of good appearance.Though lamination techniques of great use, it needs the web-like product made respectively and wrinkling and lamination processing technique equipment to produce the corrugated element that is adhered to the fluctuating on other smooth web-like product spares.

Summary of the invention

According to an aspect of the present invention, in single synthetic complex, directly produce the one or more level and smooth and smooth relatively surface elements that are adhered to one or more ripples or sinusoidal linear element.

According to a further aspect in the invention, the discrete superimposed elements of this synthetic complex can be assembled by each filamentary member of deposition on the additional fibers part, the not adhesive layer that compresses as individual course with combined optional ground, and integrally compress as multilayer module alternatively.

According to a further aspect in the invention, collapsible the combination with non-contractibility can be made by the combination of single part or various fibers or by the element of introducing as the web-like product of making in advance with the technology of non-woven or other on-the-spot generation.

According to a further aspect in the invention, at least one element of multilayer module can be made by one or more thermoplastics.

According to a further aspect in the invention, at least one element of tinkertoy module can tighten or shrinkable material is that the material of major part is made by comprising, the relatively-high temperature degree (near the melting point of material) of shrinkable material in standing stove or other device shrinks, or shrink by the method that is used to activate this shrinkage, and one deck at least of tinkertoy module can not shrink relatively.

According to a further aspect in the invention, assembly can be used for forming the roller of ripple or by utilizing the three-dimensionally shaped surface of required form by utilization---for example by knurling rolls or band, by folding, by wrinkling or by utilizing Micrexing

Technology or similar mechanical technique form sinusoidal shape.

According to a further aspect in the invention, tinkertoy module forms sinusoidal shape by utilizing transferring metal silk screen or other conveying device, conveying device can be positioned at the horizontal plane top of furnace surface conveying device, and the furnace surface conveying device is with the speed operation slower than the conveying device that raises.

According to a further aspect in the invention, the whole not bonding layer assembly that forms sinusoidal shape heats in stove or other activating apparatus of process or method, make the non-relatively shrinkage layer of shrinkable layers shrink, and become relatively flat, when cooling, non-shrinkage layer remains the sinusoidal shape that is adhered to flatness layer simultaneously.

According to a further aspect in the invention, particle assembly process join alternatively in the layer and layer between.

According to a further aspect in the invention, by careful selection material and condition, some embodiment can show very high rigidity and endurable thorn ability.The comparatively high amts of flatness layer alternately and sinusoidal layer can increase favourable result.When the structure applications occasion is used, expect especially that the selection of regulating material will comprise fire-resistant chemicals---no matter be in material, still as the chemical addition agent that separates.

According to a further aspect in the invention, the fluctuation quantity of per unit length can be enough high, makes shrinkable layers can not be punctured into fully near flat state, but because the existence of shrinkable layers still can show high rigidity and favourable architectural feature.Shrinkable layers will still have in the time of can not becoming complete flatness layer after activation than the weak sinusoidal feature of sinusoidal layer.

According to a further aspect in the invention, what can expect is, can use metal, carbonaceous, pottery or other non-traditional element is produced compound very unique and expectation.

By specify below the reference, claim and respective drawings, those skilled in the art can further understand and clear these and other feature of the present invention, advantage and purpose.

Description of drawings

Specify example embodiment of the present invention below with reference to accompanying drawings, wherein:

Fig. 1 shows the example two dimension view of the stack technology that is used for bonding two fabrics of making in advance;

Fig. 2 shows the 3-D view of the sinusoidal structured that adheres to the flat surfaces structure;

Fig. 3 has shown the view that is used for two web-like product fabric combination that have an even surface are become the processes well known of bonding 3-D stacks structure, and wherein sinusoidal linear element adheres to the element that has an even surface;

Fig. 4 shows the view that is used for smooth web-like product fabric combination is become the more complicated technology of 3-D stacks structure, and wherein sinusoidal linear element adheres to the element that has an even surface;

Fig. 5 A-Fig. 5 D shows the view of the assembly of flat elements with outer planar surface and sinusoidal linear element;

Fig. 6 A-6C shows the view of the assembly of flat elements with outside sinusoidal surface and sinusoidal linear element;

Fig. 7 has shown an assembly, and wherein, a smooth element has outstanding filamentary member, the non-relatively discrete surface of band, and this surface forms low-density lint surface;

Fig. 8 shows the view of the assembly with two relative lint face component and a corrugated element;

Fig. 9 A is presented at the view of the sinusoidal structured of wavelength relatively little in the composite component (high wave number);

Fig. 9 B is presented at the view of the sinusoidal structured of wavelength big relatively in the composite component (lower wave number);

Figure 10 A is presented at the view of the sinusoidal structured of high relatively amplitude in the composite component;

Figure 10 B is presented at the view of the sinusoidal structured of relative low amplitude value in the composite component;

Figure 11 shows the flow chart that is used for forming according to an aspect of the present invention the process of synthesizing complex;

The view of the assembly of the air lay of the staple in bulk layer that Figure 12-18 demonstration compresses alternatively;

Figure 19 shows the view of assembly of the air lay of the staple in bulk layer with layer 3 of non-woven that compress alternatively, produced on-site to Figure 22;

Figure 23 A shows the view of the assembly of the staple in bulk layer that is bonded into synthetic complex;

Figure 23 B shows the view of the assembly of the staple in bulk layer be bonded into synthetic complex and non-woven layer;

Figure 24 A demonstration is bonded into the staple in bulk layer of synthetic complex and the view of non-woven machined layer and web-like product;

Figure 24 B shows the staple in bulk layer of assembling, non-woven machined layer and the web-like product of making in advance, is bonded into the view of synthetic complex then;

Figure 24 C has shown that through shrinkable layers and non-shrinkage layer behind the activation step this moment, collapsible member was shrunk to the surface of relatively flat, but not contraction elements keeps the not sinusoidal state of contraction;

Figure 25 has shown that use air lay processing technology assembles staple in bulk shrinkable material and two non-shrinkage layers, then by being used for forming the roller moulding of ripple and the situation that activates;

Figure 26 has shown that another uses the air lay processing technology to assemble staple in bulk shrinkable layers element and non-shrinkage layer element, the situation that whole assembly is formed sinusoidal form and activates then;

Figure 27 has shown another contractile relatively non-textile element that uses air lay processing technology to assemble non-contraction staple in bulk and additional scene to make, has formed sinusoidal structured, the situation of passing through activation step then then;

Figure 28 shown by the non-shrinkage layer of deposition staple in bulk and additional collapsible web-like product, form sinusoidal structured then and the view of another synthetic complex of making through activation step;

Figure 29 shows the view that utilizes the knurling rolls with recessed surfaces assembly to be formed the exemplary method of three-dimensional sinusoidal structured;

Figure 30 shows and has utilized pleat and folding to form assembly to form the exemplary method of more obviously folding or sinusoidal structured;

Figure 31 A demonstration utilizes wrinkling technology to produce the view of the method for three-dimensional relief fabric;

Figure 31 B-C demonstration utilizes Micrex

The aspect of micro-creping processing technology produces the view of the method for three-dimensional relief fabric;

Figure 32 A-32D has shown that the transferring metal screen apparatus (the stove woven wire moves with the speed lower than transferring metal silk screen) that raises relative to moulding stove woven wire in the z direction by utilization deposits the diffusing assembly of shrinkable layers and non-shrinkage layer, makes the view of the method for synthetic complex so that assembly has sinusoidal shape;

Figure 33 shows by particle being incorporated into shaping fiber and introduces in the head and particle is added to the view of the inside of layer;

Figure 34 to Figure 48 show exemplarily particle is added to shaping fiber introduce between the head and these particles activated and bonding after synthetic complex in the diagrammatic sketch of final position;

Figure 49 shows the bending force experimental rig; And

Figure 50-the 77th, the light micrograph of the synthetic complex of example.

The specific embodiment

Though the present invention shows with reference to specific embodiment and illustrates that the present invention is not the details that is confined to show at this.On the contrary, can be on this basis, in the equivalency range of claim, implement various improved procedures and do not break away from the present invention.In addition, the embodiment that is used for showing in the drawings shows in proportion, nor the ratio shown in being limited to.

Term used herein " non-woven fabric " means a kind of like this fleece: it has the structure of being made by the individual fibers in the middle of inserting, and does not make but this structure is the mode that maybe can distinguish in order that for example occurs in weaving or mesh grid.As by the trade council that represents supatex fabric industry---INDA (U.S. nonwovens industry association) definition, the non-woven fabric fabric typically refers to mechanically, heat or chemical mode entangled fiber or fiber filament (and by with perforate membrane) are bonded to together flake structure or fiber net structure.

The non-woven fabric net can be formed by many processing technologys, for example, dries into net, spunbond by air lay, carding, fusing and becomes net, spinning to be fused into net, common moulding (Co-forming ^TM), wet moulding, scrim and netting is extruded, making hole film and other this type of processing technology form.Term " air lay " implication is that non-woven fabric Netcom super-dry air lay processing technology forms, and it uses air to carry and the staple in bulk assembly is deposited on the collection woven wire substrate of porous for example.

Term " bicomponent fibers " used herein " refer to have two kinds of component fibers; and for example such fiber: it comprises the core of being made up of a kind of material (for example polymer), and this core is encapsulated in the covering of being made up of different material (another polymer that for example has different melting points)." bi-component " fiber of some kinds can be used as binder fibre and uses, its in stove, heat afterwards or by some other activation method can be bonded to each other and be adhered on another fiber or the parts to form synthetic structure.For example, in the polymer bicomponent fibre, the polymer that comprises covering is through the fusing under the temperature more different than the polymer that comprises core (low usually) of being everlasting.As a result, the fusing owing to the covering polymer after being fit to heating (activation) and following cooling of this binder fibre provides heat bonding, keeps the expectation strength and the fibre structure feature of infusible core polymer simultaneously.As the replacement scheme of using bicomponent binder fibers, except for example pin make with mechanical adhesion methods such as hydraulic pressure winding, the multicomponent fibre of various chemical compositions and form, one pack system filament, extrudate, film, scrim, netting, particle, powder, emulsion polymer and resin also can be used for binder fibre structure and rolled article.

Term used herein " element " refers to an independent part of combining structure, assembly, compound or laminate, promptly layer, fiber, particle, filler, maybe can be combined into (for example, fusing bonding, stick bonding, by physical adhesion such as winding or sorption in inside) any other part of combining structure, assembly, compound or laminate.

Term used herein " assembly " refers to the stratiform combination of two or more parts or the element of combining structure and laminated construction.According to the present invention, composite assemblies alternatively can be by the combination technique of for example air lay, carding, for example become net, spinning fusing or fusing to dry into net, common moulding by spunbond ^TMThereby, extrude or comprise for example fiber mesh material with the direct non-woven processing manufacturing of burlap and film or other technology.These materials can be combined into the tinkertoy module of the multilayer with fiber module, then are bonded together, and produce synthetic complex structure to utilize stove or other activation step, so that layer is bonded to each other to form synthetic complex in bonding back.

Term used herein " composite structure " or " synthetic complex " are equal to the resulting structure of other method that layer is bonded together by bonded assemblies or use in stove or other devices.

Term used herein " layer " is included in the single or multiple lift in the assembly, and it can be preferably discrete fully or preferably not discrete with other layer.

Term used herein " contraction " or " contractile " are that finger element shrinks in fact in stove or when handling in other activating apparatus or the processes.

Term used herein " non-contraction " or " not collapsible " are that finger element does not shrink (for collapsible member) when processing (this can make collapsible contraction) in stove or other activation step in fact.

Term used herein " undulatory ", " sinusoidal ", " wavy " and " wavy " all are all general, all be to be used for one or more elements of illustrated components to have the shape that is similar to ripple or wavy, schematically illustrate as the Reference numeral among Fig. 2 2100.

Term " sinusoidal ", " wavy " refer to have wavy of feature of periodic waveform basically, this periodic waveform is not to be necessary for sine curve, its wavelength be between any two respective point on the continuous waveform distance (for example, two peak-to-peak distances of adjacent wave of waveform), and amplitude for the fluctuation height.Alternatively, waveform can be not with wavelength as sign, it can be with wave number as sign, wave number and wavelength are inversely proportional to, and refer to the number of repeat unit of the waveform of each unit length.Wave number is a frequency corresponding parameter spatially.Sinusoidal or fluctuation waveform needn't perfectly reappear or be perfect parallel, can be in size, have some in shape and change, and perhaps reappear waveform and have some other variation.

Term used herein " activation " can be any processing technology, no matter be to use heating furnace, or the radiation by electromagnetic energy, still by some other methods, so long as make occur between the element in one deck bonding, make and between two-layer or more multi-layered element, occur bonding and/or make contractibility produce contraction behavior (if present) getting final product.

Below with reference to figure explanation example embodiment of the present invention.

Fig. 1 has shown and has been used for adhesive 1003 the web-like product 1001 and 1002 of two relatively flats of making in advance being stacked in together simple and processes well known.Bonding appearing between the hold-down roller 1004 produces adhesive stacks 1005, its relatively flat and thinner on thickness or z direction.This structure is fine and close relatively, and machine vertically (MD) and the counter-bending ability on the transverse machine (CD) be different from that use shows in as Fig. 2, will be different at the similar laminated construction of the wavy or sinusoidal linear element of following explanation.

Fig. 2 has shown and is rising and falling to some extent on the thickness z direction 2105 and bonding to the ripple on the element 2101 of surperficial relatively flat or the 3-D view of sinusoidal linear element 2100.Low and the relatively more resistance to compression of the density of this glued construction, and the bending force that is applied on the laminated construction had different responses.

Fig. 2 also provides the label of representing x used herein, y and z direction, has shown the length 2104 (longitudinal direction of x direction or machine) of continuous assembly, wide by 2103 (horizontal direction of y direction or machine) and vertical height 2102 (z directions).Fig. 3 follows the regulation of Fig. 2 to Figure 38, its be show vertical thickness (z direction) and length (x direction) but do not have demonstration as shown in Figure 2 the machine-wide direction or the two-dimensional side view of horizontal direction (y direction).

Fig. 3 shows the view be used for the technology of the exemplary formation ripple of two web-like product mixes of making in advance that have an even surface and lamination, wherein web-like product 2300 machine vertically move roll up than fabric 2301 fast.Shown in Fig. 2 was overall, fabric 2300 passed the roller 2007 that is used for forming ripple, and became the 3-D stacks structure with fabric 2301 is bonding, and it has and is attached to element on the element that has an even surface, corrugated lifting on the z direction, as Fig. 2 illustrates ground on the whole.Final that synthesize, low according to the same glued construction global density of the smooth stack technology production shown in Fig. 1 with similar structure beguine shown in Figure 2, and the integral thickness height.The manufacturing technology that is used for producing the combining structure with this required character is used to produce for example stupefied carton of common paper pan tile, and the stupefied carton of described common paper pan tile is widely used in and comprises during carrying and protect article.Though can produce required structure, known technology requires to make the web-like product in advance with different processing technologys, makes up then and is bonded together, and causes poor efficiency and costliness.

Fig. 4 has shown the smooth web-like product 2300 that is used for making in advance, 2301,2303,2305 are combined into exemplary, the more complicated process technology of 3-D stacks structure 2306, in this 3-D stacks structure 2306, the corrugated element that replaces is attached to the element that has an even surface that for example is generally used for assembling the corrugation case.The crest that those skilled in the art will appreciate that each corrugated element can be aimed at or misalignment on the z direction alternatively with the crest of other corrugated element; And, be used for forming the pattern form of roller 2007 of ripple and the synchronization parameter of roll speed by change, the multi-wavelength of corrugated element and amplitude combination can with the smooth element combination of kinds of surface.Than Fig. 3, as illustrated in fig. 4, when the expectation number of plies of element that has an even surface and corrugated element increases, form ripple and lamination machining complexity and cost along with increase.

The present invention is different from above-mentioned technology, and provide the disposable direct processing technology of finishing of simplification, realizing that the corrugated element is adhered to these complex combination of the element that has an even surface, and this technology avoided the manufacturing complexity, and no longer needs to use the web-like product of making in advance.

In one aspect of the invention, have been found that the improvement manufacture method that is used for directly producing the combination composite, it has avoided independent combination to make the ripple and the lamination processing of web-like product.Form the staple in bulk of layering or the assembly of fiber combinations, wherein at least one divides stacked element to be made by temperature-sensitive or other shrink-down material, and at least one divides stacked element to be made by one or more non-shrink-down materials.Unbonded tinkertoy module corrugate or form sinusoidal shape in addition, and follow process high temperature or fully make contractibility be shrunk to other activating process on the surface of relatively flat, simultaneously, non-contractibility layer maintenance is bonded together with the contractibility layer becomes the ripple state of the non-contraction of synthesizing complex.The assembly of the requirement of element that the present invention has an even surface with single fabrication process and the inner positive string member of corrugated that is bonded together, and do not rely on the previous known technology of a plurality of fabrics volumes of making in advance of wrinkling separately, lamination and adhesion technique combination.

Have been found that, according to the present invention, in the disposable manufacturing technology of finishing, produce simultaneously to have and flatly can also reduce the requirement of material to make synthetic complex, and can also reduce or expense and complexity that removal is relevant with converting process with the structure corrugated element.More specifically, have realized that, when during the processing that raw material is transformed into final products, making up then, added cost and complexity when the web-like gas producing formation manufacturing separately of a plurality of independent productions of different materials.This assembly need be configured to when its along the machine vertically continuously moulding and the machinery of network for location parts synchronously during operation.In addition, have been found that being used for that these raw material are transformed into the situation that the processing technology of final products may have different intensity and extended attribute owing to different web-like product materials becomes complicated.Therefore, minimizing need be combined with the raw-material quantity of formation final products in changing processing or the cost and the complexity that need reduce the manufacturing of complicated therewith final products of any web-like product component of removal assembling.

In addition, have been found that combined airflow becomes the use of net complex also to reduce whole raw-material cost.Because web-like product raw material are often supplied with by different company, and may need to make concrete specification, therefore, often cause and be used for below transfer process and use the waste of this material of the relevant material of acquisition.In addition, when buying this material from suppliers, the supplier's administrative expenses and profit margin of being correlated with will join in the cost of final products therewith.

In addition, the use of the web-like product net of the independent moulding of assembling in lamination has added the expense relevant with laminating apparatus and jointing material, adhesive for example, and it requires the web-like products with adhesive is formed final lamination together usually.More specifically, this lamination also requires extra raw material to be provided at the minimum strength that needs in this web-like product, to guarantee the accurate of ripple and lamination processing.

The present invention has removed the needs of a plurality of web-like gas producing formations, has realized guaranteeing the synthetic complex of the whole low weight of machining stress, and has reduced the quantity of material and the cost relevant with material of whole use.

Figure 11 has shown the flow chart 800 of the exemplary step of the synthetic complex that is used to make the air lay type according to an embodiment of the invention.Square frame 802 has shown that the fiber that deposits first quantity is to limit the step of ground floor.Square frame 804 has shown the step of the fiber of deposition second quantity on the fiber of first quantity, and wherein the fibre lay-up of second quantity is on the fiber of first quantity, to form not bonding and the second layer that disperse relatively.Square frame 806 has shown goes up step with further structure multilayer with the fiber laydown of other concentration to previous layer.Square frame 807 has shown another step that the assembly of multilayer is formed corrugated or sinusoidal shape.Square frame 808 has shown the final step that makes the sandwich construction activation and be bonded together and synthesize complex structure to form.Activation step makes the collapsible member in the assembly be shrunk to the state of relatively flat, and the non-contraction elements in the assembly keeps sinus-curve simultaneously.

Fig. 5 A to Figure 10 B has shown the limiting examples of the expectation of the synthetic complex structure that is obtained by enforcement the present invention.

Fig. 5 A shows the relative simple exemplary bonded assemblies that is made of the element 5000,5001 of two relatively flats and a corrugated or sinusoidal linear element 5002, and show vertical direction (z direction) and from left to right be view (x direction) on the length direction along the machine longitudinal direction.

Fig. 5 B shows the bonded assemblies by 5003,5004,5005 and two positive string members 5006 of corrugated of element of relatively flat and the 5007 exemplary summary complexity that constitute, and has shown vertical direction (z direction) and length direction (x direction).Those skilled in the art should be realized that, each corrugated element 5006 and 5007 crest and trough and other corrugated elements can align or also can not line up in the z direction, and in having many other layering occasions many such combinations can be arranged.

Other limiting examples of the flat elements that Fig. 5 C to Fig. 6 C demonstration is otherwise made up and the tinkertoy module of sinusoidal linear element, all these examples can utilize the disposable making processing technology of finishing of the present invention to make, and need not previous known stack technology.

Fig. 5 C shows the element of relatively flat and another exemplary more complicated bonded assemblies of sinusoidal linear element, and wherein the element 5010 and 5011 of two surperficial relatively flats contacts with each other.

Fig. 5 D shows the element of relatively flat and the exemplary bonded assemblies of sinusoidal linear element, and wherein two sinusoidal linear elements 5020 and 5021 contact with each other.

The present invention also imagines following synthetic complex: have the outer surface of fluctuating and at the element of the relatively flat of complex inside.

Fig. 6 A shows that wherein the element 6003 of relatively flat is in the inside of bonding composite component by the element 6003 of relatively flat and two sinusoidal linear elements 6001 and 6002 assemblies that constitute 6005.

Fig. 6 B is presented at the element 6007 of a relatively flat in the synthetic complex and the simple assemblies 6008 of a sinusoidal linear element 6006.

Fig. 6 C has shown more complicated assemblies 6013, in this synthetic complex, have sinusoidal surface 6009 and a smooth surface 6012 of a fluctuating, and have the inner sinusoidal linear element 6010 and the flat elements 6011 of an inside, it bonds together.

Those skilled in the art should be realized that, utilization forms the formation ripple of roller 2007 of ripple and lamination by example being used for as shown in Figure 3 and Figure 4 technology changes the amplitude of sinusoidal linear element or corrugated element or wavelength will need to install and use synchronous being used for of a plurality of speed to form the roller of ripple, and described roller is corresponding with shape, wavelength and the amplitude of expectation, with the sinusoidal shape that obtains expecting in final laminates.Because difficulty that compression causes, existence aspect the fluffy low-density characteristic of the fluffy resilient web-like product that guarantees to make respectively, the perhaps change on the surface that causes owing to adhesive, perhaps since must be by lamination machinery the difficulty of processing that brings of the character of the variable stretching of unwinding and the various web-like products that move and compression, make to use to form ripple and stack technology and produce this type of assembly and may be restricted.The scheme of the application of the invention, even the very low element of density that adheres on the flat surfaces can effectively produce as needed, and compare with other element in the assembly, have very different density and physical property.

The air lay technology of using in according to one aspect of the invention that is used for deposit fiber has been avoided the limitation of this processing, advantage and flexibility are provided simultaneously, on the discrete component of assembly, to produce surface villous as required, and can not cause fine hair part do not expect compress and possible density increases, or flatten.In addition, during air lay processing, be applied to the condition that compresses of each layer by the condition of suitable selection stove, employed fiber prescription and (alternatively), can easily control the degree of the fiber initiation in each layer.

Fig. 7 shows the exemplary expectation assembly 7005 with a corrugated or sinusoidal shape fabric element 7001, and the outer surface 7000 of element 7001 is the fiber of the protrusion that extended in z direction 7002 by part and relative " lint " surface of constituting.

That Fig. 8 has shown that the inside and outside lip- deep element 8004 and 8000 by sinusoidal linear element constitutes is exemplary, complicated assemblies 8005 more, and wherein element 8004 and 8000 has relative non-discrete and low-density lint surface.The lip-deep pars fibrosa of stacked element 8000 and 8004 protrude into inner chamber 8002 and 8003.Those skilled in the art will appreciate that the cavity that is formed between the sinusoidal linear element is changeable in bonding composite construction; Hollow also can partly or entirely be filled by fine animal fibre as required significantly; Can have various wavelength and amplitude; And can in numerous tinkertoy modules and combination of elements, carry out various combinations and not break away from theme tone of the present invention.

Fig. 9 A to Figure 10 B has shown the z direction height of sinusoidal linear element and has repeated the exemplary variation of wavelength that the scheme of these the application of the invention can change at an easy rate.

Fig. 9 A has shown the example when ripple on the element 9001 that is adhered to the relatively flat in the composite component 9004 or sinusoidal linear element 9002 have relatively little wavelength (high wave number).

Fig. 9 B shows the example when ripple on the element 9003 be adhered to the relatively flat in the composite component 9005 or sinusoidal linear element 9002 have big relatively wavelength (lower wave number).

Figure 10 A is presented at the ripple of the high relatively amplitude on the element 10001 that is adhered to relatively flat in the bonding composite component 10004 or the example of sinusoidal linear element 10000.

Figure 10 B is presented at the ripple of the relative low amplitude value on the element 10003 that is adhered to relatively flat in the bonding composite component 10005 or the example of sinusoidal linear element 10002.

Shown in the flow process chart of Figure 11, according to an aspect of the present invention, this assembly that wherein sinusoidal linear element adheres on the element of relatively flat can directly be made by assembling sandwich type element deposit, wherein the one deck at least in the sandwich type element deposit can be made as with respect to other elements in the assembly and can shrink in fact, and on can bonding other element after the activation.The whole assembly that is laminated for example forms three-dimensional sine or bellows-shaped with whole assembly through processing and forming.Then, make the activation step of the assembly of moulding, make contractibility be shrunk to the surface of relatively flat (but not the element that shrinks keeps sinusoidal shape) through for example stove, and when when activation step shifts out, being adhered on other the element.

The ability that is easy to change position, prescription and the quality of the collapsible or non-contraction elements of in the complicated tinkertoy module each is the advantage of air lay method of the present invention.Special advantage is that the present invention can adapt to various raw material and the various forms (shape of for example irregular particle or cohesion piece) in the mixing formula widely; as long as because at least one stacked element is wherein shunk in fact with respect to other element; then; no matter it in conjunction with being combined together to form the sinuous assembly of particular type, is used then contraction which kind of mode, that be used for producing expectation and get final product in conjunction with the activation act of behavior.In fact, can very wide these characteristics of raw material component of the scope of application be to make us most among the present invention expecting.

The present invention can realize with many pivot weights, shape and combination, as long as can make the other relatively layer of at least one layer produce to shrink and get final product after assembly at first be formed on the z direction bossed shape or other wavy shape.No matter the activation step of which kind of form, it all is to utilize the similarly difference of the shrinkage aspect of layer of shape.In activated assembly, the normally expectation bonded to each other of all each element layers, but according to selected material, can not necessarily can there be some variations in this point; In synthetic complex, two-layer or more multi-layered between bonding minimizing---even not having bonding---also can expect.

Though depositing the exemplary method of element layer as used herein is the air lay method of forming, can expect various assemble methods.In addition, the details that is used for any concrete assemble method of before moulding and the activation deposition and the element layer of tinkertoy module both had been not limited to the method in this explanation, also was not limited to the quality and the prescription of each the stacked element in each layer.

According to the solution of the present invention, have nothing to do with the machinery of other assembly that is used to form air lay or layer and the particular content of system, synthetic air becomes web frame above other processing technology for example to have, and is used for the performance characteristic of the product that the processing technology of the lamination of a plurality of fabrics makes.In addition, be because it has reduced the cost relevant with lamination by the benefit of utilizing synthetic air to become web frame to realize, comprise cost and because the loss of the manufacturing efficient that the shutdown that the complexity of lamination processing technology causes brings from processing waste material.Can think, about 5% or more refining losses, perhaps reach 15% or more refining losses all relevant with the lamination processing technology.In addition, the speed of lamination is by different extensions, neck and the hot strength restriction of fabric to be made up.Also have the cost relevant with removing with the stack adhesive setting.In addition, can also reduce the thickness (higher density) of the whole fabric in the laminated construction, it can be unwanted.The lamination processing technology requires to store several different web-like products, and except the cost that uses a plurality of web-like production marketing merchants and transportation, supply, test and checking web-like product, it is also relevant with quality Control.In addition, as the result who himself makes processing, each fabric all has the problem of himself waste of material.

Those skilled in the art also should be clear, can use lucky a kind of chemicals type and material forms, with the design consideration product that carries out of the present invention.For example, even have the same fibre chemistry character that is used for different component, also to study the heating set handling used during the fiber manufacturing processing technic that is used in addition same staple in bulk or on-the-spot deposition cell and the difference of tensile fiber parameter, to produce the relevant difference of the contraction behavior of the discrete item in tinkertoy module when activating.Example structure can also be by the shrink-down material manufacturing with another layer layering that comprises same shrink-down material, and same shrink-down material mainly uses by being diluted in the non-relatively shrinkage layer with non-shrink-down material.The abundant weight concentration ratio that can comprise layer formula, make the material of diluent zone between pot-life relatively the shrinkage layer of higher concentration do not shrink substantially.The various prescriptions that are used for deposit fiber part (at least a fiber is thermoplastic) by the utilization according to the present invention (for example, type and quality) the air lay processing technology, according to the fiber of selecting, can realize the density of the individual course of various retractable properties, strength characteristic, surface texturisation and assembly; The details of the Weaving pattern of porous shape; Transmit and the stove woven wire; Stove is provided with; Adhesive; And the strategy that compresses that before the activation of the contraction behavior of shrinkage layer, is used for layer assembly processing.

The fiber feeding that separates by using a plurality of shaping fibers to introduce head and utilize air lay contour machining procedure example provides maximum flexibility, and can more easily change rapidly during manufacture.

For example, the binder fibre in first district of complex can have a pivot weight, and the fiber in another district can have different pivot weights, and all can be different in any or all assembled layers.Collapsible the weight concentration with non-contractibility selected according to contraction behavior, surface texturisation, intensity and the performance characteristic of required synthetic complex needs in every layer.The prescription and the feature of the quantity of material of deposition and use material can be regulated alternatively in very wide scope in every layer, handle consideration with the functional requirement and other design, cost or the processing that adapt to final synthetic complex.

Compare with other zone of synthetic complex, introduce a special quantity of material by supply with shaping fiber to every layer in air lay processing, fiber can be provided with particular performances on the protrusion surface of z direction; Useful variable comprises fineness, fold situation, shape and the chemical composition of fiber.These layers are regulated separately alternatively, and to obtain required density at the hold-down roller assembly process, it also influences the behavior of activation step.

In addition, more expensive fibrage can be adjacent to the location with the more cheap composition that is hidden in another layer, and the performance of the individual course of assembly can be selected according to the performance requirement of final use, often use more a spot of material, to compare with the structure of laminating method manufacturing by forming ripple with then making up, provide same or better functional in the resulting complex with independent manufacturing.

To Figure 22, it has schematically shown according to example system of the present invention, that can be used to form the synthetic complex of air lay type below with reference to Figure 12.

Particularly, Figure 12 provides the diagrammatic side view of exemplary fiber net and complementary fleece formation system as follows to Figure 22: this mode has shown zone that synthetic air becomes stratum reticulare is how to be formed at the top of each other when moving through corresponding net forming system.The zone of exemplary net does not show any concrete ratio or number range, and just illustrates for explanation to show.In addition, owing to some mixing of the fiber between the zone that becomes web frame at the synthetic air that occurs during the net forming processing, so actual zone may not be as shown in FIG. can clear differentiation.

Generally, be presented at Figure 12 and all shown the machine with feed surface to each the fleece formation system among Figure 22, this feed surface comprises the porous metals silk screen, and the complex net form of air lay is formed on this porous metals silk screen.Fiber is introduced the top that head is positioned at woven wire, so that controllably the part of air lay complex is transported on the silk screen.Schematically show as shade cross section among Figure 12 to 22, fiber introduce head structure become will same or any combination different fibers introducings.For example, two or more (or all) fibers are introduced head can introduce same fiber or fibre blend, or all or some fibre are introduced head and can be introduced different fibers or fibre blend.Also be provided with and optionally change fleece when roller passes system with convenient fleece.The indicative icon of the final net of the synthetic complex of air lay (and being listed in the machine below of Figure 12 in Figure 22) shows by each fiber and introduces the mesh portions that head provides, and these parts along machine vertically (MD) form the synthetic complex net of air lay.Similarly, be used for illustration purpose, be illustrated schematically in Figure 12 to Figure 22 be distinguished from each other regional different, in the air lay system of reality, these mesh portions integrate.

Specifically with reference to Figure 12, exemplary system utilizes machine 1004a to form the net that the complex 1000a by air lay constitutes.Machine 1004a comprises the conveying mechanism 1006 of support metal silk screen 1020, and the part of the complex of air lay is deposited on the woven wire 1020.A pair of upstream rollers 1008 and another to downstream rollers 1010 so that the mode that woven wire 1020 passes between every pair roller 1008 and 1010 be provided with.A plurality of fibers are introduced a length along machine 1004a and are arranged on woven wire 1020 tops.Particularly, machine 1004a comprises that four (4) individual fibers introduce heads, and it comprises that first fiber introduces 1012, second fiber and introduce the 1014, the 3rd fiber and introduce the 1016 and the 4th fiber and introduce 1018.First and second fibers are introduced 1012 and 1014 upstreams that are positioned at upstream rollers 1008, and third and fourth fiber is introduced 1016,1018 and is positioned at the downstream of upstream rollers 1008 and the upstream of downstream rollers 1010.Upstream and downstream roller 1008 and 1010 can be used as hold-down roller and uses; Gap between gap between the roller 1008 and the roller 1010 can be adjusted, and this point will become clear in conjunction with Figure 13 in the explanation of Figure 22.The machine 1004a that shows in Figure 13 is that four fibers are introduced an air lay machine, and its fiber that is shown as the basic identical amount with the same fibre composition of feeding introduces 1012,1014,1016 and 1018.Alternatively, fiber is introduced the one or more fibers that can the basic different amounts of feeding in 1012,1014,1016 and 1018, or different fiber or the fibre compositions of feeding.As shown in figure 12, machine 1004a is not used as hold-down roller (that is, kept the gap between the roller 1008 and 1010, thereby the net that passes has not therebetween been applied thrust or thrust is minimized) with upstream and downstream roller 1008 and 1010.Therefore, machine 1004a is configured to produce and has low-density relatively thick relatively fabric.

Below with reference to Figure 13, this example system of demonstration comprises the machine 1004b that is used to form net 1000b.Machine 1004b is configured to utilize upstream rollers 1008 as hold-down roller, and downstream rollers 1010 is not so used.Therefore, machine 1004b is configured to define the fabric of variable density, because introducing 1012 and 1014 zone of introducing by first and second fibers is compressed by upstream rollers, thereby these regional density have been increased, and thereby any of zone that downstream rollers 1010 has reduced or eliminated at interval by third and fourth fiber introducing, 1016 and 1018 deposition compress, so, introduce a regional leakiness of 1016 and 1018 depositions by third and fourth fiber.

Below with reference to Figure 14, this exemplary system comprises the machine 1004c of the complex net 1000c that is used to form air lay.In this system, upstream rollers 1008 and downstream rollers 1010 are all used as hold-down roller, have the thin net of highdensity relatively fabric thereby produce.

Below with reference to Figure 15, it has shown the machine 1004d that is used to form net 1000d, has only downstream rollers 1010 to use (upstream rollers 1008 is not so used) as hold-down roller.Therefore, machine 1004d provides the integral body of net to compress, thereby the same with the net 1000c that forms according to system shown in Figure 14, produces highdensity relatively thin fabric.

Below with reference to Figure 16, machine 1004e is used to form net 1000e.Machine 1004e uses upstream rollers 1008 and downstream rollers 1010 as hold-down roller simultaneously, but has the degree that compresses of variation.More specifically, upstream rollers 1008 is used as hold-down roller, and downstream rollers 1010 is provided for partly compressing.Therefore, the net that machine 1004e production density changes in gradient (as schematically showing) by the relative thickness in the zone of net 1000e, but aspect the thickness and density in the zone of netting 1000e, net 1000e (for example is different from the net 1000c shown in the net 1000b shown in Figure 13 and Figure 14, two zones at the top of each net are thicker, and typically have lower density).

Below with reference to Figure 17, machine 1004f is used to form the similar net 1000f with net 1000e shown in Figure 16.Net 1000f is different with net 1000e on the compaction degree that is provided by downstream rollers 1010, thereby produces by introduce a thicker zone that material constituted of 1016 and 1018 depositions by third and fourth fiber.

Below with reference to Figure 18, machine 1004g produces net 1000g.Except elastomer is introduced head introduces by fiber, the system that shows among the system that shows among Figure 18 and Figure 15 is identical.Particularly, elastomer is introduced 1016 by the 3rd fiber and is incorporated in the net, wherein by fiber introduce 1016 fiber of introducing with introduce by fiber 1012,1014 with 1018 fibers of introducing at least different aspect its elasticity.Owing to introduce an elasticity of 1016 fibers of introducing by the 3rd fiber, so, after passing through downstream rollers 1010, the zone of generation is tended to " rebounding " or is returned to its original shape, thereby produces by central area that surround, that volume is bigger, density is lower, basic thin zone.This zone can be arranged on any position on the thickness direction of net, comprises the top and the bottom section of net.One skilled in the art would recognize that each element that uses in layer needs not to be the staple in bulk assembly, this air lay contour machining procedure can adapt to many material shape and form factor.

Figure 19 has shown the different system component of assembly to the system that Figure 18 shows with Figure 12 to Figure 22, and its difference is that the raw material part of one or more separation is incorporated in the assembling processing technology alternatively.The part of this separation is the preformed net materials of for example non-woven fabric alternatively.Preferably, the part of separation is combined to form with the air lay processing technology at the scene, to reduce manufacturing cost.

With reference to Figure 19, machine 1004h is used to form net 1000h, and net 1000h is included in the web material between the adjacent areas that pass through the second and the 3rd fiber introducing 1014 and 1016 formation of netting 1000h.More specifically, the fiber that is provided with complementarity in machine 1004h introduces 1011, introduce the 1014 and the 3rd fiber and introduce a position between 1016 material 1009 is incorporated into second fiber, thereby net materials is incorporated into introducing the 1014 and the 3rd fiber by second fiber and introducing between 1016 zone that form of net 1000h.Therefore, except the net materials 1009 that adds was introduced between two adjacent areas of netting 1000h, final net 1000h was identical with the net 1000a that is formed by machine 1004a (Figure 12).

With reference to Figure 20, machine 1004i produces net 1000i.Net 1000i is to use upstream rollers 1008 as hold-down roller with the something in common of net 1000b (Figure 13), introduces two first areas of 1012 and second fiber introducing, 1014 deposition to compress by first fiber.In addition, net 1000i also has similarity with net 1000h (Figure 19), and promptly the net materials 1009 of Fen Liing is introduced between 1011 zone that are incorporated into by the second and the 3rd fiber introducing 1014 and 1016 deposition by the fiber of complementarity.

With reference to Figure 21, machine 1004j is used to form net 1000j, and net 1000j is compressing aspect the ratio with similar with net 1000f (Figure 17), and similar with net 1000h (Figure 19), and promptly separate mesh material 1009 is introduced 1011 by the fiber of complementarity and introduced.

Below with reference to Figure 22, machine 1004k is used to form net 1000k.Indicative icon among Figure 22 has shown can provide various ingredients (same or different components) by a fiber introducing 1011A-1011E who introduces at the shaping fiber of air lay between the head.For example, these fibers are introduced head can introduce 1012 at fiber, any block position place of 1014,1016 and 1018 upstream and downstream is provided with the introducing (for example, spunbond becomes net, net is dried in fusing or spinning is fused into net materials or film) to be used for net materials 1009A-1009E.In machine 1004k, the fiber of these complementarities is introduced a 1011A-1011E and is separately positioned on first fiber and introduces a upstream of 1012, introduce 1012 and second fiber at first fiber and introduce between 1014, introduce the 1014 and the 3rd fiber at second fiber and introduce between 1016, introduce that the 1016 and the 4th fiber is introduced between 1018 and introduce a downstream of 1018 and the upstream of downstream rollers 1010 from the 4th fiber at the 3rd fiber.Can use any combination of the fiber introducing head of these complementarities, and these fibers introducing heads can be used to introduce same component or any different component that makes up.In addition,, can be used in combination upstream rollers 1008 and downstream rollers 1010 arbitrarily, so that compress the selection zone of final net 1000k as hold-down roller though in Figure 22, do not show.Be also contemplated that, directly be formed on the web-like product base material (for example, directly being formed on the porous substrate of the spunbond net of lightweight or other suitable base material) by synthetic complex and produce article alternatively by synthetic complex with air lay with air lay.

By utilizing synthetic air other advantage into the net, for becoming net, synthetic air provides other functional characteristics, the net of promptly producing does not have directionality basically, that is to say that hot strength and other the similar physical property on vertical MD of machine and horizontal CD is basic identical.This situation with the paper of being produced by for example carding and spunbond net-forming process and many nonwoven type is different, and the net that the latter produces has directionality on intensity and structural load support performance---and MD is more much higher than CD.

Therefore, no matter be or by synthetic complex technique production, the combining structure with directionality all requires higher quantity of material, so that sufficient intensity to be provided on MD and CD (x and y) direction by stack technology.Though compare with structure with this type of other formation system, the air lay synthesis system has advantage, this type of other system's (comprising stacked) also all within the scope of the invention, and is particularly all the more so when using with the air lay system.Should be realized that, some materials (for example, the spunbond net), no matter be the web-like product of producing as separately, or the mesh element of conduct field fabrication during the manufacturing of the web-like product component (fitting together by air-laid process) of other fiber or unwinding all is ubiquitous and the charge is small.Therefore, can use this material valuably, preferably use, and alternatively particulate be added in the into synthetic complex structure with the air lay fibrous material.

Be applicable to air lay and and be suitable for that exemplary air flow lapper tool of the invention process can (MarketingTechnology Service Inc.) locates to provide, or by Denmark by the Market and Technology Services Co., Ltd in Kalamazoo city, U.S. Michigan state NeumagDenmark A/S or the Dan-Web A/S company of the Aarhus of Denmark provide.

Figure 23 A to Figure 23 B and Figure 24 A to Figure 24 B have shown the synthetic complex of making under collapsible the situation of relatively flat not having, and Figure 24 C has shown the assembly with collapsible.

Figure 23 A has shown the example components that is made of a plurality of staple in bulk layers 2310, and described staple in bulk layer 2310 assembling stacked on top of each other are bonded together in stove or in other activation step 2311 then and form single synthetic complex 2312.

Figure 23 B has shown by staple in bulk layer 2307,2309 and the non-woven layer 2315 of the direct processing of making simultaneously, 2316 example components that constitute, these layers assembling stacked on top of each other is bonded together in stove or in other activation step 2311 then and forms single synthetic complex 2318.

Figure 24 A has shown by staple in bulk layer 2408 and the superimposed elements 2407 of the non-woven processing of making simultaneously, 2409 and the assembly 2415 that constitutes of the web-like product 2410 made in advance, these layers assembling stacked on top of each other then is bonded together in stove or in other activation step 2311 and forms single synthetic complex 2410.

Figure 24 B has shown the assembly 2425 that the superimposed elements 2418,2421 of the non-woven processing of making by staple in bulk layer 2420, simultaneously and the web-like product of making in advance 2419,2422 constitute, all these layers assembling stacked on top of each other then is bonded into single synthetic complex 2426 in stove or in other activation step 2311.

Figure 24 C has shown by shrinkable layers 2331,2333,2335 with relative non-shrinkage layer element 2332,2334 sinusoidal pattern or the wavy assemblies 2336 that constitute, these layers are assembling one above the other in advance, then, activate and be bonded into single synthetic complex 2340 in stove or in other activation step 2311, make when shifting out activation step, collapsible surface 2345,2347 and 2349 that is shrunk to relatively flat, but not contractibility 2346,2348 keep being attached to the corrugated or the sinusoidal shape of the non-contraction on the element 2345,2347 and 2349 that has an even surface.

Before the expectation shrinkage activation that makes the element that assembles according to the present invention, there is multiple possibility in the wavy or bellows-shaped of utilizing known technology to make not bonding layer assembly form fluctuating.The shape, amplitude or the wavelength that those skilled in the art will appreciate that wave spare needn't be consistent especially, to form orderly at least slightly sinusoidal shape in synthetic composite component.

Figure 24 C has shown hollow region 2350,2351,2352 and 2353.According to the material that uses, these hollow region can be by from flatness layer or sinusoidal layer or fill up from both the fiber protrusions branch on surface simultaneously.Hollow region can also be caved in or partly cave in owing to multiple reason.

Figure 25 has shown according to another example embodiment of the present invention, it has shown by collapsible the layer 2512 of staple in bulk and the non-shrinkage layer 2510 of two staple in bulks, 2514 assemblies that constitute, described layer utilizes air lay shaped portion 2550 to assemble with superposeing each other, then, utilization is used for forming the roller 2007 formation sinusoidal shapes of ripple, and is then bonding in stove or other activation step 2311.Assembly is bonded into single synthetic complex 2520, wherein, collapsible 2524 surface that in synthetic adhesive complex 2520, is shrunk to relatively flat, and two non-contractibilities 2522, the non-shrinking bellows-shaped that 2526 maintenances are basic also is adhered on the surperficial contractibility 2524 of relatively flat, to form cavity 2528,2530.

Figure 26 has shown the more complicated illustrative methods of utilizing air lay moulding section 2650 to form the staple in bulk assembly, described staple in bulk assembly is by collapsible 2610,2614,2618 and non-contractibility 2612,2616 constitute, and whole assembly utilization is used for forming the roller 2007 formation sinusoidal shapes of ripple, pass through stove 2133 or other activation step then, make collapsible 2610,2614,2618 non-relatively contractibilities 2612,2616 shrink, thereby obtain by still being sinusoidal non-contractibility 2632,2630 and ( formation cavity 2634,2636 attached to it, 2638, the synthetic complex 2620 that is bonded that the shrinkable layers 2622,2624,2626 of relatively flat 2639) constitutes.

Those skilled in the art further should be realized that, the present invention for example can comprise alternatively by extruding the thermoplasticity that is fiber or other form or non-thermoplastic material and the superimposed elements of produced on-site, and alternatively also can be in conjunction with the web-like product spare of making in advance, it does not all break away from theme tone of the present invention.

Figure 27 has shown exemplary air lay forming method, it utilizes the non-high shrinkage 2712 of air lay moulding section 2750 depositions, 2716, and sedimentary facies is to non-woven 2710 of the direct processing of shrinking, 2714,2718, and whole assembly the roller 2007 that utilization is used for forming ripple form wavy after, in stove 2311 or in other activation step, activate, make contractibility 2722,2724,2726 non-relatively contractibilities 2732,2730 shrink, thereby obtain by still being sinusoidal non-contractibility 2732,2730 and attached to itly (form cavity 2728, the shrinkage layer 2722 of relatively flat 2739,2736,2738), 2724,2726 bonded complexes 2720 that constitute.

Figure 28 has shown the non-shrinkage layer 2812 that utilizes staple in bulk, 2816 and the web-like product 2810 made in advance, 2814,2818 form another illustrative methods of loose assembly by air-laid process, wherein, whole assembly at first forms sinusoidal shape, activation in stove or in the activation stage 2311 then, make the non-relatively contractibility of contractibility shrink, thereby obtain by still being sinusoidal non-contractibility 2830,2832 and the bonded complex 2820 that constitutes of the shrinkable layers 2822,2824,2826 of relatively flat attached to it.

Figure 29 shown the knurling rolls 2970 that utilize hold-down roller 2980 and have the groove surfaces feature will form by the assembly 2966 that element constitutes corrugated or moulding, with form alternatively with by the similar 3D shape of roller making shape that is used for forming ripple.Knurling rolls 2970 use outstanding surface characteristics alternatively, rather than the molding character of indent, and can use suction areas 2071 to be applied to pattern on the assembly 2920 with further enhancing alternatively.

Those skilled in the art will appreciate that having many kinds of modes gives assembly with the bellows-shaped of expectation, and this moulding can change not only in the z direction, and can change at x and y direction.For example, the shape of many these type of patterns and concrete projection can be utilized and be used for making assembly to form projection on roller, belt, woven wire or other expectation device of this shape originally or the pattern of indent is given assembly with the image of this moulding, and the pattern of this projection or indent can be at x, continuous or irregular on y and the z direction, it does not all break away from theme tone of the present invention disclosed herein.In addition, it is similar each other that the top of final molding assembly 2920 and lower surface do not require on pattern or quality, or identical on the top of the synthetic complex of producing and bottom, or form pattern to obtain continuous wave-like on transverse machine.

Figure 30 has shown other method, and it has utilized pleat technology 3030 that assembly is formed sine, relatively tangible foldable structure, to form generally and the similar three-dimensional wave shape shape 3020 of sinusoidal structured of being made by the roller that is used for forming ripple.

Figure 31 A has shown by utilizing the wrinkling technology of for example using in the production of cotton paper usually to make the other method of irregular three-dimensional relief fabric.Assembly 3166 utilizes pressure roll 3170 to be adhered on the drier 3172.Creping doctor 3154 makes fleece bend to three-dimensional wave shape shape 3160, keeps the 3D shape of wrinkling assembly then by the take up roll 3155 that slowly moves.

Figure 31 B to Figure 31 C has shown other method, and it is by utilizing the Micrex that uses in paper and non-woven industry

Micro-creping processing technology (it is used for applying to the fabric assembly the wavy shape and the pliability of z direction) forms three-dimensional relief fabric 3198.Generally, Micrex

Micro-creping technology and other similar processing technology depend at two or more and move or the different acceleration of static surface, the roller that moves with different speed (generally slower) or the net between the band, be to move the slower bobbin-winding machine that batches then, it preserves the 3D shape of assembly.This known technology that is used to produce little fold also is applicable to moulding assembly of the present invention.

Figure 32 A to Figure 32 D shown according to of the present invention, utilize the transferring metal screen apparatus of selling the rising that provides by the Dan-Web A/S company in for example Denmark Aarhus city before activation step, to form a method for optimizing of the stacked assembly of air lay.This conveying device works by using suction box 3264,, providing vacuum by the porous metals silk screen band 3210 that moves, the porous metals silk screen band 3210 that this moves on speed with stove woven wire 3259 and forming metal silk screen 1006 close synchronization.In normal running, the effect of conveying device is to promote frangible staple in bulk assembly from the woven wire of moulding section, then assembly is deposited to intactly with activate thereon subsequently with bonding stove woven wire on.

In the normal running of air lay technology, conveying device woven wire 3210 is only slightly high than the plane of stove woven wire 3259, the approaching thickness that equals the staple in bulk assembly of its height apart from this plane, and conveying device woven wire and stove woven wire are with very close speed operation, when activation in stove and bonding after, produce in the industrial production the synthetic compound fabric in typical plane.According to an aspect of the present invention, by compare the height to remarkable rising conveying device woven wire 3210 with stove woven wire 3259 at z, and, make that the material in the assembly is piled into wavy by significantly reduce the speed of stove woven wire with respect to the conveying device woven wire.The further advantage of this technology is in time and simply to regulate, thereby, utilize the setting of simple machine control software, by regulating the delivery head and the speed of the relative stove woven wire of conveying device, can make assembly have required amplitude and wave number or wavelength.

Figure 32 A has shown the preferred exemplary method that forms synthetic complex by the loose establishment of component of sedimentary deposit 3216, wherein, the conveying device woven wire 3210 that utilizes the plane of relative stove woven wire 3259 on the z direction, to raise, and stove woven wire 3259 moves with the speed that is lower than conveying device woven wire 3210, thereby the three-dimensional wave shape that will expect amplitude is given the assembly that element constitutes, and makes whole assembly form wavy structure 3226 like this.

Figure 32 B has shown the exemplary method that forms synthetic complex by deposition staple in bulk establishment of component, wherein, utilization is compared with Figure 32 A at the relative few transferring metal silk screen 3210 of z direction rising, makes whole assembly formation compare the lower wavy structure 3226 of amplitude with 3226 of Figure 32 A.

Figure 32 C has shown the exemplary method by the synthetic complex of deposition staple in bulk establishment of component, wherein, utilization is moved stove woven wire 3259 faster, that simultaneously still move slowlyer than transferring metal silk screen 3210 than the stove woven wire 3259 among Figure 32 A, whole assembly is formed compare the lower wavy structure 3240 of frequency with 3226 of Figure 32 A.

Figure 32 D has shown the exemplary method by the synthetic complex of deposition staple in bulk establishment of component, wherein, utilization is moved slower stove woven wire 3259 than the stove woven wire 3259 among Figure 32 A, makes whole assembly formation compare the higher wavy structure 3286 of frequency with 3226 of Figure 32 A.

It should be appreciated by those skilled in the art, the amplitude of sinusoidal shape and wave number or wavelength can be in very wide range regulation, and can successfully obtain on thickness and pivot weight, to have the assembly of bigger variation by the rising height of conveying device and the relative velocity of transferring metal silk screen and stove woven wire are applied independently variation.

The expectation on the other hand of some embodiment of the present invention is added particle in the synthetic complex to.Can expect that also various particles and other material enter into the special benefits of the various high expectations that can bring between each layer or each layer, thereby be stabilized in the layer and the high concentration of the granular materials in the cavity that after the activation of the behavior of contraction, produces.

Figure 33 has shown at the assembly process of layer and has introduced 1012 with the shaping fiber at 3320 places, position, 1014,1016,1018,1019 add particle 3330 to be added with particle all individual courses 3302,3306 alternatively, 3310, view in 3314,3318, and show in the final integral position of these particles in synthetic complex 3348, bonding back.Cavity 3304,3308,3312 and 3316 keep relative hollow and do not have particle.Any combination that can expect that the layer of particle is arranged or not have the layer of particle.

Figure 34 has shown the view of the example complex of the particle 3430 with interpolation to Figure 38, its be by the assembly process of each layer, forming assembly wavy or sinusoidal shape before, add particle to five shaping fibers and introduce 1012,1014,1016,1018, between 1019 and make.In final structure, has particle in the cavity that forms between the element in the synthetic complex after activation.Particle in the final structure can be positioned in the cavity to prevent big moving abundantly.

It should be appreciated by those skilled in the art that many independent smooth surface elements can make up in z direction and other sinusoidal linear element alternatively, and final the many of cavity may make up all in theme tone of the present invention.In addition, those skilled in the art will appreciate that particle and the many combinations thereof that to add many types and shape, and do not break away from theme tone of the present invention.In fact, what can expect is, carefully select particle in each cavity a plurality of locations and particle is positioned over these positions the function that provides by these particles can more effectively be provided.What also can expect is that the mixture of mixing and the particle of one-component keep and interior other the dissimilar particle separation of whole synthetic composite construction.Provide and comprise alternatively with fiber or low-density lint surface portion and fill the opening of this cavity or cavity open relatively and hollow is expected, so for example can perhaps provide the space for expanded granular (for example superabsorbent particles that uses as baby' diaper) is provided in the space of z direction expansion for crosslinked resin or the foamed material that can in follow-up processing, include or activate alternatively.In addition, have been found that by enforcement of the present invention and strengthened the stability of bulky powder in assembly.In addition, can in cavity, keep the particle of high concentration very and move indistinctively.

The example that can be incorporated into the particle in the open cavity that limits between sinusoidal shape layer and the flatness layer comprises thermoset particles, thermoplastic granulates and cementaceous particle, these particles can work under the condition significantly different with the condition that makes synthetic complex activation (for example, make at least one layer material become in shrinking with the structure of finishing relatively flat).At these not under on the same group the condition, particle can after chemical reaction (for example, under the situation of Thermocurable particle, take place crosslinked), phase transformation (for example, melting under the situation of thermoplastic granulates) or solidify (for example, running under the influence of humidity) at the cementaceous particle.The example of cementaceous particle comprise have similar cement, glued joint or the character of adhesive type, and comprise Portland cement, gypsum etc.

Exemplary embodiment in the table 1 shows performance of the present invention, these embodiment make by the air lay moulding of staple in bulk assembly, its utilization is used to activate with bonding baking oven and utilizes than stove silk screen mobile phase to fast fluctuating transferring metal screen apparatus, shown in Figure 32 A to Figure 32 D.According to the prescription that shows and utilize the specific machinery setting that shows in the table 1, use be used for making the embodiment of the invention, have five shaping fibers and introduce heads, middle hold-down roller, the staple in bulk component transfer device that can raise in the z direction and four regional adjustable stoves and (produce sample in the table 2 by the suitable air lay formation system of the Market and Technology Services Co., Ltd (Marketing Technology Service Inc.) provides) in Kalamazoo city, U.S. Michigan state.

Table 2 also reference has shown the overall shape of the synthetic complex that obtains after the activation and the accompanying drawing of final general structure.Figure 50 to Figure 77 is the light micrograph that has shown the side view of the example structure of amplifying 2 times and 4 times.

All be suitable for though be applicable to many other fibers of enforcement of the present invention, the thermoplastic adhesives that are used in the example embodiment can be by the typical bicomponent binder fibers of commercial means acquisition for the air lay industry.1.55 " Trev " be bought and be abbreviated as to the polyester fiber of the T-255 grade of Denier (denier) can from the Trevira GmbH of the Augeburg of Germany table 1.ESC806A AL AD grade is applicable to from the Fibervision A/S in Athens city, U.S. Georgia state buys and is abbreviated as " ALAD " table 1.Fortrel6 Denier polyester fiber can be bought from the Wellman Co., Ltd in the Darlington city in the South Carolina state of the U.S. and be abbreviated as " PET " table 1, wherein also uses the polyester of 15 Denier, and it is abbreviated as " 15d PET ".The length of employed synthetic fibers is about 6mm, but longer and shorter fiber selects to be used for enforcement of the present invention alternatively, and the fiber that can use many types is as binding fiber.The average length of softwood cellulose fine hair paper pulp grade (can buy and be abbreviated as " pulp " from the Rayonier Co., Ltd in Jesup city, Georgia state) is about 3mm.The present invention expects that many fibers can use, and can be for than longer or shorter at the fiber of this explanation.Be used for component of the present invention and can be combination hydrophilic, hydrophobic or hydrophilic and hydrophobic material.The suitable fiber that is used for using in the present invention comprises many cellulose fibres (for example wood pulp and cotton-wool), modified cellulose fibre (for example staple fibre and Lyocell), cellulose acetate, hemp, jute, flax, polyester, polypropylene, polyethylene, PLA and many other is synthetic, mineral (for example, glass) and the natural material that can use or mix with other non-fibrous material use separately.These compositions can also be mixed together to realize required attribute with various prescriptions.

Table 1 has shown that being deposited on each air lay shaping fiber between erecting stage introduces the height of surface rising of the state of every square metre gram number of every kind of fibre fractionation in the head, hold-down roller and pressure (being designated as " Comp A " and " Comp B " in table 1), the relative stove woven wire of transferring metal silk screen and the speed of transferring metal silk screen and stove woven wire.Prescription of listing in the table 1 and mechanical condition (comprising the delivery head of rising and the relative velocity of transferring metal silk screen and stove woven wire) satisfy the condition of the air lay fiber laydown structure shown in Figure 32 A integral body.The furnace of using in activation step for all examples that show in the table 1 is set at 140 degrees centigrade in three initial stove zones, and is set at 155 degrees centigrade in the 4th stove zone.

Figure 49 has shown the view of testing equipment 4900 of the bending resistance of the complex that is applicable to that evaluation is thick relatively.This device is the remodeling of Thwing-Albert QC-1000 cupping machine model OC-1000, and it is generally used for estimating the hot strength of paper and other fiber.(model: RSB-1) 4907 be connected to flexible metal silk screen 4905, flexible metal silk screen 4905 is connected to clip 4910 by lifting bolt 4985 to be connected to T-A load unit pivot fixator 4901, that have 2000 gram abilities.Clip 4910 forms by transforming with the long-tail folder from the middle-sized office that Quill company obtains, and it transform as and comprises the lifting bolt that is fixed to long-tail folder central part.The weight of whole clip assembly is 18 grams, and clamps sample 4950 at one centimetre of 4920 place of leading edge of distance sample 4960.Sample 4960 to be tested is fixed to the 5.2cm height, and the back-up block 4940 that 15.5cm is wide, described back-up block 4940 are connected to move and support 4950, and link position is apart from 1.5cm place, its center, shown among the figure 4990.Weight is 400 grams, be of a size of the gripper shoe 4955 that 15.5cm multiply by 5.5cm and clipped on the back-up block 4940, and between insert shim washer 4930, shim washer 4930 equals the malcompression thickness of sample 4960.Sample 4960 with size that 5cm multiply by 10cm exposes 5cm from the edge of back-up block 4940, shown in Reference numeral 4915.

At test period, load cell at first makes zero, and then, begins test: make to move and support the 4950 speed decline 2cm with 3.87cm/min, and make sample 4960 deflections to apply power on load unit 4970.The high scale of the power that measurement records at duration of test, be the high scale at measurement terminals 2cm place and be recorded in the table 2 as bending force.

Table 2 has shown the final pivot weight and the density of the synthetic complex of producing at the ratio of the bending force of MD and CD orientation measurement and MD and CD bending force and according to the prescription in the table 1 and condition.

Table 2

Row #	The synthetic complex accompanying drawing of reference	Light micrograph figure	Final pivot weight gsm	Final thickness cm	Final densities g/cm 3	MD bending force kg	CD bending force kg	The MD/CD ratio
									1	Fig. 1	50	138	0.13	0.11	0.0062	0.0064	0.969
2	Fig. 1	51	212	0.17	0.12	0.0322	0.0286	1.126
									3	Fig. 5 A	52	116	0.05	0.23	0.0026	0.0048	0.542
4	Fig. 5 A	53	144	0.10	0.14	0.0014	0.0068	0.206
									5	Fig. 5 A	54	204	0.20	0.10	0.0172	0.0362	0.475
6	Fig. 5 A	55	497	0.21	0.24	0.3450	0.4450	0.775
									7	Fig. 5 A	56	511	0.26	0.20	0.2290	0.2908	0.787
8	Fig. 5 A	57	532	0.51	0.10	0.2322	0.2696	0.861
									9	Fig. 5 A	58	930	1.10	0.08	0.3234	1.0128	0.319
10	Fig. 5 B	59	878	0.48	0.18	0.6130	0.6738	0.910
									11	Fig. 5 B	60	949	0.35	0.27	0.8420	0.9862	0.854
12	Fig. 5 B	61	959	0.90	0.11	0.5292	0.6682	0.792
									13	Fig. 5 B	62	1068	0.63	0.17	0.8550	1.0990	0.778
14	Fig. 6 A	63	535	0.54	0.10	0.2248	0.3276	0.686
									15	Fig. 6 A	64	657	0.91	0.07	0.1712	0.3300	0.519
16	Fig. 6 B	65	171	0.13	0.13	0.0062	0.0186	0.333
									17	Fig. 6 B	66	377	0.62	0.06	0.0722	0.1606	0.450
18	Fig. 6 B	67	379	0.42	0.09	0.1198	0.2838	0.422
									19	Fig. 6 B	68	456	0.62	0.07	0.0818	0.2162	0.378
20	Fig. 6 C	69	709	0.66	0.11	0.4888	0.7200	0.679
									21	Fig. 6 C	70	733	0.87	0.08	0.3720	0.5816	0.640
22	Fig. 6 C	71	796	1.10	0.07	0.3378	0.4950	0.682
									23	Fig. 7	72	158	0.37	0.04	0.0092	0.0162	0.568
24	Fig. 8	73	271	0.17	0.16	0.0522	0.0708	0.737
									25	Fig. 9 B	74	247	0.24	0.10	0.0386	0.0534	0.723
26	Figure 10 A, 9A	75	267	0.31	0.09	0.0536	0.0664	0.807
									27	Figure 10 B	76	260	0.26	0.1	0.0534	0.0766	0.700
28	Figure 36	77	1137	0.63	0.18

Though utilized the example demonstration that shows in the table 1 and some embodiments of the present invention be described at this, but embodiment just provides by the mode of example, and part is because the structure very widely with various types of materials is produced in concrete flexibility of the present invention easily.This flexibility guarantees those skilled in the art can implement other application, alter mode and variation and replacing on this basis and not break away from theme tone of the present invention.In addition, be used for showing in the drawings that the embodiment of selection does not have the display size scope, and be not limited to ratio that shows in the drawings or the prescription that embodiment uses in table 1.

More than preferred embodiment has only been considered in explanation.Those skilled in the art and practitioner can use the present invention or make improved procedure of the present invention on this basis.Therefore, should be appreciated that, show in the drawings embodiment and above explanation just be used for illustrative purposes, rather than limit the scope of the invention, its appended claims of explaining according to the principle of patent law limit, and comprise the principle clause of equivalent.

Claims (23)

1. a species complex, it comprises the structure with two layers or a plurality of layers, at least one layer in the described layer comprises sinusoidal shape layer, and at least one layer in the described layer comprise the layer of relatively flat, layer being made up of the material after the contraction that is fused to described sinusoidal shape layer of described relatively flat.

2. complex according to claim 1, wherein, at least one layer is the web-like product material of making in advance.

3. complex according to claim 1, wherein, at least one layer is the non-woven material of field fabrication.

4. complex according to claim 1, wherein, described at least one sinusoidal shape layer comprises two sinusoidal shape layers, wherein said two sinusoidal shape layers lay respectively at two external position places of described complex.

5. complex according to claim 1, wherein, described at least one smooth layer comprises two smooth layers, wherein said two smooth layers lay respectively at two external position places of described complex.

6. complex according to claim 1, it has the open relatively cavity that is limited between described sinusoidal shape layer and the described smooth layer, and described cavity can selectively comprise particle.

7. complex according to claim 6, wherein, described cavity comprises particle, and wherein said particle local positioning fully, to prevent significant moving.

8. complex according to claim 6, wherein, described particle is the mixture of carbon or carbon and other particle.

9. complex according to claim 6, wherein, described particle is cementaceous cement, gypsum or materials similar, when water or some other fluid or preparation were applied to described particle, described particle reacted to bond to together.

10. complex according to claim 6, wherein, the cavity of described opening comprises particle, and described particle is the material that can react under selected predetermined condition.

11. complex according to claim 10, wherein, described particle is selected from thermosetting, thermoplasticity or cementitious material.

12. a species complex, it comprises the composite structure with at least one layer, and described at least one layer has interior section and two outer surfaces, and at least one of described two outer surfaces has outstanding fiber.

13. a processing technology that is used to make complex, described processing technology comprises: at least one layer of deposition on base material; This at least one layer is set to sinusoidal shape; And activate this at least one layer, so that the component shrinkage in this at least one layer and/or be adhered on other the element in the described complex.

14. processing technology according to claim 13, wherein the processing technology of at least one layer of deposition is that dry gas stream becomes net or other non-woven processing technology on base material.

15. processing technology according to claim 13, wherein, complex synthesizes.

16. a processing technology that is used to make complex, described processing technology comprises: will comprise at least one layer of collapsible and comprise that at least one layer of non-contractibility is assembled into a stacked assembly; Described stacked assembly is formed sinusoidal shape; Activate described stacked assembly, make to form a synthetic complex, and described collapsible contraction to be forming the layer of relatively flat, and described at least one layer of non-contractibility that comprise remains in the sinusoidal state that does not shrink.

17. processing technology according to claim 16, wherein, described packaging technology is the air lay processing technology, and wherein said collapsible comprise staple in bulk, and described non-contractibility comprises staple in bulk.

18. a processing technology that is used to make complex, described processing technology comprises: will comprise at least one layer of the collapsible fibre deposition of being made by thermoplastic and comprise that sedimental at least one layer of non-high shrinkage of being made by thermoplastic is assembled into stacked assembly; Described stacked assembly is formed sinusoidal shape; In stove with the described stacked assembly of enough temperature-activated, this temperature makes the described collapsible fibre deposition of being made by thermoplastic with respect to the described non-high shrinkage shrink deposition of being made by thermoplastic, and can make described at least one layer that comprises the collapsible fibre deposition of being made by thermoplastic and comprise that sedimental described at least one layer of the non-high shrinkage of being made by thermoplastic is bonded together when cooling.

19. a processing technology that is used to make complex, described processing technology comprises: will comprise at least one layer of collapsible staple in bulk and comprise that at least one layer of non-contraction rolled article is assembled into stacked assembly; Described stacked assembly is formed sinusoidal shape; And activate described stacked assembly, so that described collapsible staple in bulk shrinks and/or is adhered on other the element in the described complex.

20. a processing technology that is used to make complex, described processing technology comprises: will comprise at least one layer of non-contraction staple in bulk and comprise that at least one layer of collapsible rolled article is assembled into stacked assembly; Described stacked assembly is formed sinusoidal shape; And activate described stacked assembly, so that described collapsible rolled article shrinks and/or is adhered on other the element in the described complex.

21. processing technology that is used to make complex, described processing technology comprises: will comprise that at least one layer of staple in bulk and at least one other layer are assembled into stacked assembly, wherein this at least one other layer be included in this assembling process during the non-woven fabric of produced on-site; Described stacked assembly is formed sinusoidal shape; And activate described stacked assembly.

22. a processing technology that is used to make complex, described processing technology comprises: will comprise at least one layer of shrinkable material and comprise that at least one layer of non-shrink-down material is assembled into stacked assembly; Utilization forms sinusoidal shape by the device that transferring metal screen apparatus and moulding stove woven wire constitute with described stacked assembly, wherein said transferring metal screen apparatus raises on the z direction with respect to described moulding stove woven wire, and described moulding stove woven wire moves slowlyer than described transferring metal screen apparatus; And activate described stacked assembly so that shrinkable material is shunk and/or shrinkable material is adhered on other the element in the described complex.

23. a processing technology that is used to make complex, described processing technology comprises: a layer or a plurality of layer are assembled into stacked assembly, and the one deck at least in the wherein said layer comprises particle; Described stacked assembly is formed sinusoidal shape; And bonding described stacked assembly is to produce synthetic complex.

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