CN101796248A - 通过单层织造织物的超声波间隙焊接形成织物接缝的方法 - Google Patents

通过单层织造织物的超声波间隙焊接形成织物接缝的方法 Download PDF

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CN101796248A
CN101796248A CN200880105926A CN200880105926A CN101796248A CN 101796248 A CN101796248 A CN 101796248A CN 200880105926 A CN200880105926 A CN 200880105926A CN 200880105926 A CN200880105926 A CN 200880105926A CN 101796248 A CN101796248 A CN 101796248A
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fabric
seam
welding
soldering tip
littler
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CN101796248B (zh
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约翰·J·拉冯德
珍妮弗·L·鲍登
莱恩·F·克洛尔
约瑟夫·博特略
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Albany International Corp
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114Single butt joints
    • B29C66/1142Single butt to butt joints
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    • B29C65/08Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
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    • B29C66/72General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729Textile or other fibrous material made from plastics
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    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352Thickness, e.g. very thin
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    • B29C66/9221Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by measuring the pressure, the force, the mechanical power or the displacement of the joining tools by measuring the pressure, the force or the mechanical power
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/9261Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools
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    • B29C66/9261Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools
    • B29C66/92651Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools by using stops
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    • B29C66/929Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/961Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F1/00Wet end of machines for making continuous webs of paper
    • D21F1/0027Screen-cloths
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/71General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832Reciprocating joining or pressing tools
    • B29C66/8322Joining or pressing tools reciprocating along one axis
    • BPERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及单层织造织物的超声波间隙焊接。具体而言,本发明涉及一种使用可控间隙来超声波焊接织物的纱线接缝末端的方法。基于焊接深度和焊接能量,机械止动部件(15)用于将焊头(26)和砧座之间的距离或间隙控制到预定水平。通过增加另一程度的控制,本发明的超声波间隙焊接技术能够获得比常规接缝、甚至使用胶合改善的那些接缝更坚固的织物接缝,并且有益于通过点焊或沿着织物纱线的末端形成织物接缝。

Description

通过单层织造织物的超声波间隙焊接形成织物接缝的方法
技术领域
本发明涉及使用独特的超声波焊接技术(称为超声波间隙焊接)来形成单层织造织物的织物接缝。
以引用方式并入
本文中所涉及的所有专利、专利公开、文件和/或文献以引用方式并入本文,并且它们可用于本发明的实施中。
背景技术
在造纸过程中,在造纸机成形部,通过将纤维浆沉积到移动的成形织物上成形纤维素纤维网,纤维浆也就是纤维素纤维的水分散体。浆体中大部分的水通过成形织物排出,而纤维素纤维网则留在成形织物的表面。
刚成形的纤维素纤维网从成形部进入压榨部,压榨部包括一系列压榨压区。纤维素纤维网被压榨织物支撑,或者通常情况下位于两层这样的压榨织物之间,穿过压榨压区。在压榨压区中,纤维素纤维网受到压缩力的作用,该压缩力从其中将水挤出,并使网中的纤维素纤维彼此粘附,使得纤维素纤维网转变为纸幅。水由该一层压榨织物或多层压榨织物所吸收,并且理想的情况是不回到纸幅中去。
纸幅最终进入干燥部,干燥部包括至少一个可转动的干燥转鼓系列或烘筒系列,这些转鼓或烘筒由蒸汽在内部进行加热。干燥织物引导刚成形的纸幅以弯曲路径依次绕行该系列中的每个转鼓,且干燥织物将纸幅紧贴在转鼓的表面。加热的转鼓通过蒸发作用降低纸幅的含水量至所需的水平。
应该了解的是,成形、压榨及干燥织物(有时都称为纸机织物(PMC))在造纸机上都采取无端环(endless loop)的形式,并且都起到传送带的作用。应该进一步了解的是,纸幅生产是一种以相当快的速度进行的连续过程。也就是说,在成形部,纤维浆连续地沉积到成形织物上,而刚生产出的纸幅在离开干燥部后就被连续地卷绕到辊筒上。
单层织造织物也可以形成为工程织物。单层织造织物可以为成形、压榨、干燥、空气穿透干燥(TAD)或工程织物,其用于(包括但不限于)通过诸如纺粘法或水缠绕法之类的方法来制备非织造物,或用于湿法处理,例如DNT带、或淤泥过滤带等、或织品整饰带,其接缝均匀性和完整性很关键。
当织物在造纸机、空气穿透干燥机(TAD)或其他工业设备上运转,且织物承受机器方向(MD)的拉伸时,编织或交织以形成接缝的织物接缝末端或纱线端部易于回拉。为了减小这种接缝“回拉”,接缝中的纱线末端有时使用粘合剂与相邻纱线粘合。然而,粘合剂不能足够对抗机器运转条件,随时间仍会发生回拉或纱线滑移。同样,在使用其他增强方法(例如缝合PMC、TAD或工业织物的末端)的情况下使用粘合剂,也不能获得理想的接缝完整性和均匀性。
此外,在机器方向测量时,使用常规技术形成的接缝区域的宽度,通常为3.5英寸至20英寸之间的值或更高。由于多种原因,理想的是能够减小接缝区域。
图1(a-d)示出了与常规接缝形成技术有关的问题,其中,两个织物边缘的末端在接缝区域“重叠”,以及标识出关键点12(图1a),在这些点处,这些末端可在机器方向“回拉”,并且末端本身可能突出于纸幅侧表面。最终,如箭头所示,由于织物内的局部应力增加,导致在重叠区域的滑移增加(图1b),并且在织物的接缝区域内出现了完全滑移及孔洞16(图1c)。因此,接缝的重叠区域通常通过人工胶合18(图1d)来加强,从而增加其强度;然而,胶合是比较费时费力的方法。由于其较低的精度,还难以将胶料仅仅限制在重叠纱线上。另外,由于织物的挠曲,胶料最终会失效和/或磨损。
因此,需要不同或改进的方式强化接缝纱线末端,并因此强化接缝强度。
一种强化织物的接缝纱线末端的可能技术为焊接,例如超声波焊接。超声波是指超过人类听觉范围(即>20,000Hz)的声音,超声波焊接是指使用声波将材料熔合。然而,超声波焊接经常产生不可接受的接缝形成结果,例如纱线过度熔融、接缝渗透性降低和由于局部收缩而引起的织物变形。
其他缝合方法可在下列参考文献找到:
美国专利No.4,032,382涉及一种用于将热塑性单丝材料接合的方法和装置。两根长丝在装置的沟槽中结合在一起。它们暴露于沟槽中侧面压力的高频振动中,所述沟槽的尺寸对应于长丝的初始直径。结果,得到直径接近于初始材料的接合物。
美国专利No.4,401,137涉及具有无痕的环形销接缝的成形织物,所述销接缝有切边的“尾部”,其因此可以由超声波焊接以增加接缝的强度。
美国专利No.4,501,782涉及另外一种方法,其以完全刚性的方式将边缘的织物经纱的末端结合。将经纱末端置于相互交叉的位置,并且以连续方式穿过织物进行超声波结合。接缝结合要求在该操作后具有与织物本体相同的厚度。
然而,该接缝对于造纸中的要求是不可接受的,因为其引起纸张中的痕迹和/或导致不均匀的排水。如果这种接缝用于TAD织物,因为棉纸网很薄,纸网断裂的风险会很高。
美国专利No.5,464,488涉及一种在两个塑料织物层之间形成坚固并具有挠性的结合的方法,该方法要求可控地使用超声波焊接设备。将纱线软化,但不熔融,并且在该过程中彼此结合。这样的结合不是脆性的,而是变得挠性并且有利,结果不易于出现现有技术存在的结合中的破裂和断裂。
然而,该接缝无法用于开放结构,例如TAD织物。这种织物要求接缝更像常规接缝,其接缝性能应该接近于织物本体(其对于性能是必须的)。而提出的接缝是改善过的。
美国专利No.5,571,590提供了一种造纸织物,其具有机器横向(“CD”)接缝,该接缝通过单层织造基材元件的端部和在共同方向从末端延伸的端部重叠而形成;同时,将末端从端部切下,并且端部沿着共同切线熔融结合。
美国专利No.5,713,399提供通过螺旋卷绕织造织物条带(其比所需织物宽度窄)而制得的PMC。该条带在至少一个侧边上具有横向纱线的未结合端部的侧面边缘。该边缘在相邻圈的条带的边缘之下或之上。这样获得的螺旋连续接缝通过超声波焊接而封闭。
美国专利No.5,731,063提供具有机器横向接缝的造纸毡,该接缝由单层织造基材元件的端部和在共同方向从端部延伸的末端形成。同时,末端从端部切下,并且端部沿着共同切线熔融结合,这类似于美国专利No.5,571,590。
美国专利No.6,162,518涉及类似于专利5,713,399的螺旋卷绕的PMC。将至少一根连接线在加热结合开始前设置在边缘的突出线部分上。
美国专利No.6,702,927涉及提供通过螺旋卷绕织造织物条带(其比所需PMC宽度窄)而制得的PMC。该织物条带具有第一侧边和第二侧边,沿着侧边分别为第一唇缘和第二唇缘。各唇缘具有至少一个与横向纱编织的纵向纱。第一间隙和第二间隙分别与第一唇缘和第二唇缘相邻并靠其内侧,间隙处缺少纵向纱,但其横向纱将唇缘结合到条带本体。螺旋卷绕的唇缘重叠在相邻圈的间隙上,形成接缝,该接缝可通过超声波结合或其他方式封闭。
公开的美国专利申请No.2003/0221739涉及一种PMC,其在销接缝中使用至少一个预成型的环或圈以结合织物的端部、从而形成无端环。这些基础织物的端部可通过压紧、预挤压和密封进行前处理和/或后处理以稳定端部。超声波熔融或其他方式也可用于加强和提供缝合区域中的光滑表面。
尽管超声波焊接相对于常规接缝形成技术(例如缝合或胶合)具有许多优点,但是之前部分所述的超声波焊接技术存在一些缺点:常规超声波焊接基于改变多个参数,时间、能量和距离。因此,本领域仍需要一种方法,其能够获得具有可接受的表面光滑度和强度的织物接缝,还易于使用以及适于较宽范围的织物类型。
注意该申请中对于任何文献的引用或证明,并不是承认这种文献作为现有技术为本发明构成启发。
发明内容
本发明涉及在单层织造工业织物(例如PMC织物、空气穿透干燥(TAD)织物、工程织物、用于织品整饰加工(例如输送)的织物/带、或制革工艺中的带),本发明涉及在其中形成接缝的方法。该方法包括本文中称为超声波间隙焊接的超声波焊接,其包括下列步骤:设定焊头和砧座之间的距离;将待焊接的材料置于焊头和砧座之间;以及使用超声波能量焊接该材料的局部,直到到达止动部件,然后在厚度没有进一步损失的条件下,在该间隙处连续焊接预定的时间,或直到预定量的能量被吸收。
本发明的目的是在纱线之间形成可靠的结合,该结合比仅仅使用常规缝合方法获得的结合更坚固。本发明的另一目的是在织物内形成更好的接缝完整性,其焊接的接缝区域在机器方向比对应的常规接缝窄,甚至窄于通过胶合增强的接缝。
本发明的另一目的是,在机器方向对于相同长度的接缝而言,提供具有更坚固和/或更耐久的接缝的织物。优选地,在机器方向测定的接缝宽度为通常接缝或使用相同强度的常规技术形成的接缝的宽度的小于1的比率。该比率可以为0.7或更小,优选为0.5或更小,最优选为0.3或更小。例如,如果“X”为根据现有技术或常规缝合方法形成的在机器方向的接缝的宽度,则在相同强度的条件下,根据本发明形成的接缝的宽度为,例如0.7X或更小,优选为0.5X或更小,最优选为0.3X或更小。
本发明的另一个目的是使用本发明的超声波间隙焊接技术来增强诸如工业织物(例如造纸布,特别是干燥织物)中使用的销接缝和直列式螺旋缝。销接缝(其还需要将机器方向纱线重新编织进织物本体,从而具有由于纱线滑移和脱出而失效的可能)也可通过本文所述的超声波焊接技术来改善。在这种接缝中,形成接缝环本身的机器方向纱线可被焊接或熔合至机器横向纱线,从而防止它们在使用中经受操作张力而脱出。
通过消除与常规超声波焊接法有关的缺点,本发明的超声波间隙焊接技术能够获得具有足够强度的光滑的织物接缝,并且有益于通过点焊或沿着织物末端形成织物接缝。
本发明还涉及通过超声波间隙焊接形成织物接缝,所述超声波间隙焊接包括:设置机械止动部件以控制焊头的焊嘴和砧座之间的距离,使单层织造缝合和结合的织物的纱线末端对齐,将对齐的纱线末端置于焊头和砧座之间的接缝中,将焊头和砧座之间的距离调节到固定的预定间隙,以及在该间隙处,在纱线或织物的厚度没有进一步损失的条件下,使用超声波能量以预定的时间焊接织物的纱线末端,或直到预定量的能量被纱线吸收。
本发明包括使织物的纱线末端回拉和接缝末端磨损最小化的方法,该方法包括使用超声波焊接织物的接缝末端。
本发明还涉及使用所述的方法在使本文中所述的经纱重叠最小化至没有经纱重叠的情况下将织物的相邻经纱的两端彼此焊接和/或与它们横越的机器横向纱线焊接。
附图简要说明
现在将参照附图来更加完整详细地描述本发明,其中下面标出的同样的参考标号表示同样的元件和部件。
图1(a)-1(d)示出了与常规接缝形成有关的问题;
图2(A)示出了根据本发明的实施方案的超声波间隙焊接的方法;
图2(B)示出了根据本发明的实施方案的超声波间隙焊接的方法;
图3是使用根据本发明的一个方面的超声波间隙焊接来制备织物的实施例;
图4是根据本发明的实施方案的织物的剖视图;
图5是示出接缝和互锁位置的原理的图;
图6比较了常规胶合的织物和由根据本发明的一个实施方案的超声波间隙焊接形成的不同互锁长度处的织物接缝的断裂强度;以及
图7A和7B示出了使用本发明实施方案获得接缝厚度的保持和改善的接缝强度。
发明详述
本发明涉及本文中称为超声波间隙焊接的超声波焊接方法,该方法包括下列步骤:通过(例如)设置机械止动部件或利用其他方式控制焊头和砧座之间的距离,从而控制焊接深度,将待焊接的材料置于焊头和砧座之间;以及使用超声波能量焊接该材料局部,直到焊头到达预定深度或间隙,然后在该间隙距离处,在纱线厚度没有进一步损失的条件下,以预定的时间继续焊接,或直到预定量的能量被吸收。在间隙焊接中,机械止动部件(未示出)可用于控制焊头能够到达砧座的最近距离。换句话说,机械止动部件控制超声波焊头可以穿入待焊接的织物的深度。该焊头和砧座之间的距离为间隙。当焊头到达机械止动部件时,在纱线或织物厚度没有进一步损失的条件下,其继续在该间隙处焊接一定时间或施加预定的能量。当施加超声波能量时,该材料保持压缩状态。这抑制了纱线坍塌,并允许更多能量进入焊接中,但不会过度焊接、厚度减小、过热,并且不会导致纱线材料性能(例如分子取向)的损失。例如,如果织物厚度为1.0mm,则可设定机械止动部件,使得焊头的焊嘴和砧座之间留有的间隙为0.4mm。然后将0.6mm的焊头焊接到织物中。这允许使用时间或能量模式来使得焊接中能量增加。然而,该任务能控制焊头穿入的深度或砧座穿入的深度。在任何情况下,砧座和焊头的焊嘴之间的间隙确定了这样形成的焊缝深度和焊缝强度。还必须考虑焊头运动(振动)的振幅来计算间隙。
图2(A)示出了根据本发明的一个实施方案的超声波间隙焊接。就此而言,应用超声波焊头10,其使用高频超声波能量来焊接织物。使用砧座20作为支承装置,其上放置待焊接的织物30。基于待焊接的织物的厚度和需要焊接的深度,将超声波焊头10降低至预定水平。图2(B)进一步示出本发明的超声波焊接中使用的装置。该装置包括超声波焊或本领域中通常称为超声波组件装置14(或声组件装置)的装置。组件装置14由三部分构成,即转换器22、增压器24和焊头26。在组件装置14中,围绕增压器的环28夹在组件装置支承器25内。设定机械止动器15,以防止支承组件装置中点(neutral point)或增压器的环的组件装置支承器25或夹子从所需的点进一步向下移动。当超声波焊开启时,焊头的焊嘴在该设定点的上面和下面以一定的振幅振动。然而,当超声波焊关闭时,机械止动器15为焊头10和砧座20之间设定固定距离。例如,如果要使部件1和2焊接在一起,基于部件的厚度和所需焊接的深度,将止动器15设定为具有预定高度。当组件装置14开始向下移动时,超声波焊嘴关闭,在焊头接触样品后很快就达到预定负载值。该负载是通过(例如)安装在组件装置外壳上的压力传感器(例如测压元件)来测定的。在该点超声波能量被打开。应注意,组件装置外壳(此处由夹入其中的增压器24的环28来表示)在该点没有接触止动器15。随着焊接的继续,焊接产生的热结合焊头在部件上的向下压力而产生的热,引起焊接区域中的材料厚度降低,直到组件装置外壳25撞击到止动器15为止,从而防止纱线或织物厚度的进一步降低。然而,超声波能量保持为开启,并且继续进行焊接。在超声波能量关闭后,焊接部分通常在压力下保持预定时间,以使它们能够冷却并固化在一起,这获得改善的物理性能,例如强化焊接区域。然后收回组件装置14,从而完成间隙焊接。
使用时间、能量或距离来控制标准焊接。例如,如果满足特定的触发力,机器按照设定的时间、或设定的能量、或进入织物中某一距离进行焊接。超声波间隙焊接技术能够产生更坚固的结合和可接受的纱线变形,并且允许在织物的整个宽度上持续焊接(因为所有的焊接参数都被固定),以及允许增加附加程度的控制,其在更大的可接受的加工条件的窗口下有助于更坚固的加工。
本发明在形成单层织造工业织物的接缝中具有特别应用,单层织造工业织物为例如PMC、TAD织物、工程织物、或用于诸如轧光的织品整饰处理的织物/带或皮革带。然而,其他应用也是可行的。就此而言,图3为使用根据本发明的超声波间隙焊接技术焊接织物30的实施例。如果纱线末端位于织物的织造接缝内,则焊接发生。一些织物具有10,000或更多个这样的纱线末端。参见图4中织物30的剖视图,其示出了焊接的纱线末端和与机器横向纱线的焊接。被焊接于其中的织物30的厚度为0.9mm,并且将砧座和超声波焊头之间的间隙设定为0.4mm。从图3和图4可以看出,本发明的技术使焊接工艺具有精确度和厚度均匀性。
焊头和砧座之间的间隙也通过待焊接的材料测定。在本发明的一个实施方案中,待焊接的材料为织物,并且焊头和砧座之间的间隙为织物厚度的约30%至约55%。在本发明的进一步的实施方案中,焊头和砧座之间的间隙为初始织物厚度的约40%。还可以想像适用于所述目的的其他间隙距离。
注意,在造纸机布中,初始织物厚度可位于约0.5-3.5mm的范围内。对于工程织物,初始厚度可以位于约0.8mm至6.0mm、或更大的范围内。
例如,如图5所示,在机器方向各焊缝的实际长度取决于各互锁区域中平行节的数量、以及经纱和纬纱的尺寸、和它们的密度(数量和间隔)。然而,这仅仅示出了接缝和互锁位置的原理。实际图案取决于布的本体中的编织图案和与此相关的端点的可能分布。各焊缝的宽度还取决于细丝直径和纬纱或机器方向纱线间隔。焊缝可制得尽可能小,以保持织物的特性和相关纸张或其他制得的产品的特性。
对于通过本文中所述的方法形成织物接缝,由于TAD织物的性能,使用TAD织物是优选实施方案。织物接缝并不沿其自身折回;而是织物接缝与常规单层织造和缝合的织物类似,在缝合织物中,织物纱线的末端被编织进入对面的织物(例如销接缝织物)的对应端。
不论单层织造织物为TAD织物或是为工程织物,接缝强度和均匀性的性能以及纱线末端在织物的背侧上或机器运行侧上的位置,对于用于它们期望目的的许多产品都是很重要的。
根据本发明形成的织物接缝末端可以是任何长度和/或宽度,其取决于焊头的尺寸。末端尺寸可以随着新产品而改变,并且还存在下列事实:目标为使末端更短,并且机器方向的接缝区域本身尽可能小。与在织物的机器方向相同长度的常规接缝相比,使用本发明的超声波焊接方法的结果是能够形成更坚固和/或更耐久的接缝。优选地,在机器方向测定的接缝宽度为通常接缝或使用相同强度的常规技术形成的接缝的宽度的小于1的比率。该比率可以为0.7或更小,优选为0.5或更小,并且最优选为0.3或更小。例如,如果“X”为根据现有技术或常规缝合方法而形成的在机器方向的接缝的宽度,则在相同强度的条件下,根据本发明形成的接缝的宽度为(例如)0.7X或更小,优选为0.5X或更小,最优选为0.3X或更小。
在本发明的一个实施方案中,焊缝仅由各互锁中的两个纱线末端构成,并且局部结合至互锁区域中的机器横向纱线。
注意,单层织造织物(例如TAD织物和工程织物)通常包括单丝股线或聚合物纱线,例如聚酯、聚丙烯、聚酰胺(尼龙)和聚偏二氟乙烯(PVDF)。
如上所述,在单层织造织物中,接缝纱线末端易于在机器运转状况下回拉。用于粘合纱线接缝末端的标准粘合剂还允许一定程度的纱线回拉随时间发生。超声波焊接利用比标准胶合方法高两倍或三倍的强度来锁定接缝末端。可接受的是,超声波焊接能够导致织物厚度至多55%的减少和获得坚固的结合。然而,不可接受的结果是,焊接区域太大、纱线的过度熔融、和织物的整体变形,因此需要设定合适的参数。
注意,本文中所述的超声波间隙焊接技术产生更坚固的织物接缝,其具有可接受的变形量。例如,图7A是在80%的焊头运动的振幅下使用基于时间的通常的超声波焊接技术和本发明的0.4mm的超声波间隙焊接技术的比较,示出了TAD织物随时间变化的厚度保持。图7B比较了分别通过两种技术形成的两种织物的拉伸强度。图7A和7B示出使用本发明的超声波间隙焊接技术来获得的改善的接缝强度,由此保持了织物厚度并且提高了接缝强度。
还要注意,本发明能够使接缝纱线末端的磨损降低。接缝末端通常比织物本体磨损更快,因为它们易于比织物平面更高凸出。通过将末端降低并保持在织物平面之下,本文中所述的超声波间隙焊接方法有利地减少了纱线末端先于织物本体磨损的可能性。
另外,本发明包括使织物中的接缝末端的末端接缝回拉最小化的方法,该方法包括超声波间隙焊接。
本发明还涉及使用本文中所述的方法来改善接缝强度。通过所述超声波间隙焊接工艺形成的接缝具有下列益处:接缝更短(在机器方向测定),并更坚固,由此降低纸张产生纸痕的可能性,例如,或防止纱线末端移位造成面巾/纸巾中形成孔洞。
本发明还涉及改善接缝的完整性。例如,在使用织物时,重要的是织物在(例如)生产面巾纸或纸巾的机器上运转时,接缝区域能够保持其完整性。每个纱线末端都是重要的,本发明建议的方法可用于特定位置的具有预定图案的特定纱线。使用该方法的结果是,其所制得接缝纱线末端相对于胶合的纱线末端更不易失效。例如,可将接缝纱线末端区域按照需要制成厚度低于初始织物。保持织物接缝的完整性能够增加织物的有效运转寿命。尽管已经讨论了单层织造织物的接缝,但是本发明的超声波焊接技术可用于其它类型的接缝,例如销接缝,其中形成接缝环本身的机器方向纱线可被焊接或熔合至机器横向纱线,从而防止它们在使用中的操作张力下回拉,因此改善了接缝强度以及应力或负载分布的均匀性。
下面将通过非限制性实施例来进一步描述本发明。
实施例
实施例1
使用40kHz超声波间隙焊,在40微米的振幅下将TAD织物暴露达500ms的焊接时间和1秒的保持时间(即,在焊接后以及使焊头提升之前,焊头在焊接位置停留1秒)。接缝区域上的测量压力为144kPa,触发力(TRS)为111N。
处理的结果为,使TAD织物具有强化的接缝纱线末端(参见图3),其在造纸机上进行的试验运转中经历最小的接缝纱线末端回拉。另外,所得TAD织物的接缝末端具有比胶合接缝大的多的强度。
图6比较了胶合和超声波间隙焊接织物的接缝在互锁区域的不同长度织物接缝的断裂强度。明显地,与常规胶合的织物接缝、特别是在接缝中互锁的胶合的机器方向长度为中等或较短时,使用本发明的超声波间隙焊接方法焊接的织物具有更高的强度。
因此实现了本发明的目的和优点,尽管本文中公开和详细描述了优选的实施方案,但是其范围和目的不应受限于此;而是其范围应理解为受到所附权利要求的限制。

Claims (26)

1.一种焊接具有接缝区域的工业织物的方法,该方法包括下列步骤:
确定焊接过程中焊头和砧座之间的预定间隙;
在所述焊头和所述砧座之间放置待焊接的织物接缝区域的末端;
将所述焊头和所述砧座之间的距离调节至所述预定间隙;以及
通过施加预定时间的能量或直到预定量的能量被所述接缝区域末端吸收,在所述预定间隙处,对所述织物的所述接缝区域进行焊接。
2.根据权利要求1所述的方法,其中所述织物选自:PMC织物、TAD、工程织物、用于诸如轧光的织品整饰处理的织物以及制革的织物。
3.根据权利要求1所述的方法,其中所述焊头和所述砧座之间的间隙为被焊接的织物的初始厚度的30%至55%。
4.根据权利要求1所述的方法,其中所述织物为单层织造织物。
5.根据权利要求1所述的方法,其中所述预定间隙由机械止动部件控制。
6.根据权利要求1所述的方法,其中与通常接缝或使用常规技术形成在所述织物的机器方向长度相等的接缝相比,所述焊接的接缝区域更坚固和/或更耐久。
7.根据权利要求1所述的方法,其中在机器方向测定的所述接缝区域的宽度占通常接缝或使用相同强度的常规技术形成的接缝的宽度的比值为0.7或更小,优选为0.5或更小,并且最优选为0.3或更小。
8.一种降低织物中接缝末端区域磨损的方法,该方法包括下列步骤:
超声波焊接所述织物的纱线末端,通过将焊头的穿入限制到预定间隙,以及确保所述纱线末端在所述织物平面下,所述焊接被控制到所述焊头和砧座之间的所述预定间隙。
9.根据权利要求8所述的方法,其中所述织物的纱线末端焊接在一起,具有最少的经纱重叠。
10.根据权利要求8所述的方法,其中所述织物选自:PMC织物、TAD、工程织物、用于诸如轧光的织品整饰处理的织物/带、以及用于制革的织物/带。
11.根据权利要求8所述的方法,其中所述焊头穿入被焊接的织物的初始厚度的30%至55%。
12.根据权利要求8所述的方法,其中所述织物为单层织造织物。
13.根据权利要求8所述的方法,其中与通常接缝或使用常规技术形成在所述织物的机器方向长度相等的接缝相比,所述焊接的接缝末端区域更坚固和/或更耐久。
14.根据权利要求8所述的方法,其中在机器方向测定的所述接缝末端区域的宽度占通常接缝或使用相同强度的常规技术形成的接缝的宽度的比值为0.7或更小,优选为0.5或更小,并且最优选为0.3或更小。
15.根据上述方法形成的工业织物中的接缝,该方法包括下列步骤:
确定焊接过程中焊头和砧座之间的预定间隙;
在所述焊头和所述砧座之间放置待焊接的织物接缝区域的末端;
将所述焊头和所述砧座之间的距离调节至所述预定间隙;以及
通过施加预定时间的能量或直到预定量的能量被所述接缝区域末端吸收,在所述预定间隙处,对所述织物的所述接缝区域进行焊接。
16.根据权利要求15所述的接缝,其中所述织物选自:PMC织物、TAD、工程织物、用于诸如轧光的织品整饰处理的织物/带、以及用于制革的织物/带。
17.根据权利要求15所述的接缝,其中所述焊头和所述砧座之间的间隙为被焊接的织物的初始厚度的30%至55%。
18.根据权利要求15所述的接缝,其中所述织物为单层织造织物。
19.根据权利要求15所述的接缝,其中所述预定间隙由机械止动部件控制。
20.根据权利要求15所述的接缝,其中所述织物的末端焊接在一起,具有最少的经纱重叠。
21.根据权利要求15所述的接缝,其中与通常接缝或使用常规技术形成的在所述织物的机器方向长度相等的接缝相比,所述焊接的接缝区域更坚固和/或更耐久。
22.根据权利要求15所述的接缝,其中在机器方向测定的所述接缝的宽度占通常接缝或使用常规技术形成的接缝的宽度的比值为0.7或更小,优选为0.5或更小,并且最优选为0.3或更小。
23.根据权利要求15所述的接缝,其中所述末端在所述织物平面下。
24.根据权利要求1所述的方法,其中所述接缝为销接缝或直列式螺旋缝。
25.根据权利要求15所述的接缝,其中所述接缝为销接缝或直列式螺旋缝。
26.根据权利要求8所述的方法,其中所述接缝为销接缝或直列式螺旋缝。
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CN106029022A (zh) * 2014-01-10 2016-10-12 尤妮佳股份有限公司 吸收性物品的片状构件的超声波熔接装置和超声波熔接方法
CN106029022B (zh) * 2014-01-10 2019-08-02 尤妮佳股份有限公司 吸收性物品的片状构件的超声波熔接装置和超声波熔接方法
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CN112074400A (zh) * 2018-04-13 2020-12-11 精电舍电子工业株式会社 超声波焊接方法、利用超声波焊接方法焊接而成的结构体、超声波焊接装置

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