CN102245358B - 成形筛 - Google Patents

成形筛 Download PDF

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Publication number
CN102245358B
CN102245358B CN200980151544.5A CN200980151544A CN102245358B CN 102245358 B CN102245358 B CN 102245358B CN 200980151544 A CN200980151544 A CN 200980151544A CN 102245358 B CN102245358 B CN 102245358B
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China
Prior art keywords
rubber
forming screen
layer
thermoset
methods
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Expired - Fee Related
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CN200980151544.5A
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CN102245358A (zh
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P·E·托马斯
S·鲍尔
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Feiteshi Film Products Co ltd
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Tredegar Film Products LLC
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Priority claimed from US12/316,645 external-priority patent/US20100151170A1/en
Application filed by Tredegar Film Products LLC filed Critical Tredegar Film Products LLC
Publication of CN102245358A publication Critical patent/CN102245358A/zh
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    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/26—Perforating by non-mechanical means, e.g. by fluid jet
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
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    • B29C51/22—Thermoforming apparatus having movable moulds or mould parts rotatable about an axis
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  • Engineering & Computer Science (AREA)
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  • Health & Medical Sciences (AREA)
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  • General Health & Medical Sciences (AREA)
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  • Veterinary Medicine (AREA)
  • Forests & Forestry (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)

Abstract

包括硬橡胶层的成形筛复合体，所述橡胶的肖氏D硬度为12-90，优选33-90，最优选46-60，在优选的实施方式中，包括塑料或金属支承层，与所述硬橡胶结合形成复合体。成形筛可以是平面的或圆柱形的，带有大量孔或通孔以及精密结构图案。还公开了制造所述成形筛的方法。

Description

成形筛
发明背景
本发明涉及成形筛。
成形筛是用来制作有孔成形膜的穿孔装置。有孔成形膜是塑料膜，对该塑料膜进行加工在膜上产生孔或孔洞。有孔膜通常分为两类：三-维膜和平面膜。所有三维结构的膜具有标称厚度，但本发明的“三-维膜”具有表面结构，能对所述膜提供超过标称厚度的更大的厚度。通常，这些表面结构具有记忆效应，这样只要不超过膜的变形限度，这些表面结构在被压力或张力变形之后能恢复形状。相反，平面有孔膜仅仅是带有孔洞的膜，缺少具有“三-维膜”特征性三维记忆效应的表面结构。
本领域中有几种制造有孔膜的方法。可以用任意在膜中添加孔洞的方法制造平面膜。这些方法通常是使用销钉或其它模压的机械方法在前体膜中产生孔洞。对于三-维膜，两种最常用的方法是真空成形和液压成形(hydroforming)。专利文献例如US 39391 35和US 4324246中列举了一种真空成形方法，它使用真空在膜的一侧产生负压，在膜的相反一侧产生相应的正压。压差使得膜被吸入成形筛中的孔洞从而得到孔。液压成形方法，如US 4609518所述，使用高压喷水枪来产生冲击膜的液体流从而得到孔。
无论是液压成形法或是真空成形法，本领域已知要将膜支撑在穿孔结构上，本文中表示为成形筛。所述成形筛具有纹理化的表面，纹理化的表面能在成孔过程中转化到膜上。成形筛通常用金属或塑料制成。金属筛的优点是比塑料筛更坚固更结实，与塑料筛相比能更好地散热，这意味着使用金属筛通常能加快生产线速度。但是，金属筛比塑料筛更昂贵。此外，很难(如果有可能的话)在金属筛的表面产生复杂且精密的设计或结构。
然而，虽然在塑料筛上可形成精密结构，但保持精密的纹理成为问题。具体地，塑料筛对在直接浇注工艺中用来制造膜的聚合物的熔融温度很敏感。由于精细纹理和结构没有明显的质量，它们无法承受热，精细特征很容易消失。此外，很多用来制造所述筛的塑料树脂是水溶性的，因此在液压成形方法中使用时由于水逐渐溶解所述筛，所述筛会随着时间降解。
本领域需要低成本，耐久的塑料筛，即使经受直接浇注工艺中熔融聚合物的高温，也能承受并保持精密结构和纹理，在液压成形方法中耐降解；因此同时适合在直接浇注真空成形法和液压成形法中使用。
发明内容
在一个实施方式中，本发明提供的成形筛包括穿孔成形筛，所述穿孔成形筛包含肖氏D硬度为12-90的热固性橡胶。
在一个实施方式中，所述热固性橡胶包括硬橡胶。
在一个实施方式中，所述热固性橡胶包括氢化丁腈橡胶(hydrogenatednitrile butadiene rubber)。
在一个实施方式中，本发明提供的成形筛包括支承体，所述支承体在其表面上具有热固性橡胶层或热固性橡胶涂层。
在一个实施方式中，本发明提供的成形筛包括塑料支承体，所述塑料支承体在其表面上具有热固性橡胶层或热固性橡胶涂层。
在一个实施方式中，本发明提供的成形筛包括金属支承体，所述金属支承体在其表面上具有热固性橡胶层或热固性橡胶涂层。
在另一个实施方式中，所述成形筛包括穿孔平面成形筛。
在另一个实施方式中，所述成形筛包括穿孔圆柱形成形筛。
在一个实施方式中，所述成形筛包括由缩醛树脂制成的塑料支承体和外部热固性橡胶覆盖物或热固性橡胶层。
在一个实施方式中，所述成形筛包括由铝制成的金属支承体和外部热固性橡胶覆盖物或热固性橡胶层。
附图简要说明
图1是本发明的圆柱形成形筛的透视图。
图2是通过图1中线和箭头2-2观察到的截面图。
图3是本发明另一个实施方式的平面筛的截面图。
图4是圆柱形筛与多孔心轴接触时的截面图。
发明详述
本发明一个实施方式中公开的成形筛是穿孔的。所述穿孔筛特别适合用来制造用于卫生应用的有孔成形膜，例如吸收制品中的面层。吸收制品中的面层位于靠近使用者皮肤的位置。因此，需要关心所述面层的触觉，这是因为会产生那种消费者不喜欢的塑料接触皮肤的湿粘感觉。此外，塑料膜带有的光感也被认为是一个负面特征。因此，从审美的角度来说表面质地也很重要。
在另一个实施方式中，本发明的成形筛是非穿孔的。如上所述，本发明的筛接受精密细节的能力比金属制成的筛更强。这种精密结构是希望得到的，通常对在膜上产生相应的表面结构和纹理是必要的。除了上述触觉感受和降低光度之外，本发明的包含精密像差(aberration)的筛可以用于形成“鲨鱼皮肤”或其他精密图案来促进或抵御生物粘附，如美国专利第US 7143709号所述。
参考图1描述本发明一个实施方式的成形筛。所示实施方式中，成形筛10包括具有内层14和外层16的圆柱形组件12。内层14和外层16彼此紧密连接，这样筛10包括粘结的结构单元。在所示具体实施方式中，成形筛10是穿孔的，包括大量互相间隔的孔18。
参考图2描述沿图1中线和箭头2-2观察到的成形筛10的横截面。图2中可以看到内层14和外层16之间的紧密关系。还可以看到大量同时穿过外层16和内层14的穿孔18。这种构造中，真空施加到成形筛10的内部会在筛10的外部产生负压，将迫使空气通过穿孔18。空气流会使得施加在成形筛外部的膜在与穿孔18对应的区域破裂。此外，在成形筛10的外部施加高压水流，迫使施加在外部表面的膜进入穿孔18并破裂，从而在膜上得到孔。
图3显示成形筛的另一个实施方式，它示出平面成形筛的一部分的截面图。图3中成形筛110与上述实施方式类似，包括具有内层114和外层116的平面组件112，内层114和外层116彼此紧密相连。在具体实施方式中，成形筛110还包括大量同时穿过外层116和内层114的通孔或穿孔118。图3中还可以看到，附图标记120表示外层116上的区域包含的精密像差或表面结构。这些精密像差120可以是突起、压花、凹陷或成形筛表面其它类型的像差。这种表面像差120可以仅位于成形筛的部分表面，或者需要时位于整个表面。
在一些实施方式中，内层14有热塑性树脂制成。本领域已知合适的材料包括但不限于：聚丙烯、丙烯酸类树脂、聚碳酸酯、聚醚醚酮(PEEK)、聚酯、缩醛树脂(例如Delrin树脂，购自特拉华州惠明顿的E.I.杜邦内穆尔公司(E.I.duPont de Nemours & Co.))和其混合物及掺混物。优选缩醛树脂，特别是Delrin树脂。
在一些实施方式中，内层14由金属制成。本领域已知合适的金属包括但不限于：铝、镍、铜、冷轧钢、碳钢、不锈钢、或任意有色金属，以及其合金。
外层16是天然的或合成的热固性橡胶，其肖氏D硬度为12-90，优选33-90，最优选46-90，取决于预期的用途。例如，如果成形筛在压花工艺中用作夹具辊，该橡胶的硬度需要足以承受与相对-辊接触时的理想的或预期的力，这是本领域已知的。合适的热固性材料包括硫化的天然橡胶、氯丁橡胶(neoprene rubber)、硅橡胶(silicone rubber)、氟弹性体、聚氨酯(urethane)、氢化丁腈橡胶(HNBR)和乙烯丙烯二烯M-类(EPDM)橡胶(ethylene propylene diene M-class rubber)。优选的橡胶是硫化的天然橡胶，具体是一种通过很长时间硫化橡胶制备得到的硫含量为30％-40％的硬橡胶。一种已知的这种材料是“硬橡胶(ebonite)”，这是由于伊伯尼特国际公司(Ebonite Internationa)用它来制造保龄球。另一种优选的橡胶是HNBR。
EPDM是一种在例如屋顶薄膜，橡胶软管等应用中广泛使用的弹性体。M-类表示在ASTM标准D-1418中的弹性体分类。“M”类包括具有多亚甲基型饱和链的橡胶。目前制造EPDM橡胶中使用的二烯是二环戊二烯、乙叉降冰片烯和乙烯基降冰片烯。EPDM橡胶的乙烯含量为约45％-75％。乙烯含量越高，聚合物的加载可能性越高，能更好地混合和挤出。在过氧化物固化过程中，这些聚合物与其无定形对应物相比交联密度更高。二烯的含量可以不同，为2.5wt％至高达12wt％。
如果需要，可以将热导材料，包括碳纳米管或金属颗粒例如氧化铝等，分散在橡胶材料中来改进橡胶层的热导性。
在一个实施方式中，成形筛包括热固性橡胶的穿孔组件，所述热固性橡胶的肖氏D硬度为12-90，更优选33-90，最优选46-60，不包括任何支承层。
所述成形筛可以用多种方法生产。如果成形筛是平面的，塑料板或金属板和预定尺寸、形状和厚度的橡胶可以使用任意合适的粘合剂胶粘在一起。优选的是氰基丙烯酸酯粘合剂。
如果所述筛是圆柱形的，成形筛可以用不同的方法制造。第一种方法中，将具有预定厚度的塑料或金属材料支承板切割为对应于理想圆周的预定尺寸。再将支承板沿接缝滚轧和焊接来形成圆柱体。再将橡胶板用氰基丙烯酸酯粘合剂或其它合适的粘合剂粘结在支承圆柱体上。
在第二种方法中，首先将支承板粘结在橡胶板上，再将复合板滚轧和焊接来形成圆柱体。成形之后，优选将圆柱体进行加热老化(退火)来赋予圆柱体记忆效应。在使用塑料作为支承层的实施方式中，形成接缝的热焊接通过热切刀、超声接合或其它合适的方法来完成。目前已知的用于形成焊接接缝的技术包括电弧焊、TIG焊接和其它方法。某些情况下软焊(soldering)也是合适的。为得到最终圆柱体理想的容差，可以将所述筛置于车床或其它合适的装置中并机械加工成最终的尺寸。类似地，如果需要的话可以在使用橡胶层之前机械加工塑料层。
在其它实施方式中，可以通过将热固性橡胶的溶液或分散体成形筛涂覆在塑料或金属的板或圆柱体上来制备成形筛。在这种实施方式中，大部分情况下所选的塑料不能适应用来将热固性橡胶退火的温度。因此，所选的用于涂层的橡胶必须能在比用作下覆层的塑料的熔点低的温度下交联或固化。
在成形筛仅包括热固性橡胶而不包括塑料下覆层的实施方式中，可以将所述橡胶挤出或注塑，必要时再机械加工来形成圆柱体或其它理想的形状。
以下将结合图4描述制造仅包含热固性橡胶的筛的一个示例性方法。如图4所示，多孔心轴221用金属箔(例如铝或镍箔)包覆来得到金属层222。也可以使用薄金属圆柱体来代替箔包覆，但通常会不合理地增加成本。优选地，所述心轴以螺旋方式包覆。但也可以用其它方式包覆所述心轴。由于使用的金属和橡胶类型，防止橡胶材料与所述箔粘结是必须的或者是理想的。这种情况下，将聚合物膜层223，优选聚酯膜(例如购自E.I.杜邦内穆尔公司的Mylar)膜包覆在铝箔上。
然后将带状橡胶挤出到箔222(或保护膜层223)上，或通过橡胶涂覆工业中其它常规的方法施加，从而形成橡胶层216。例如，带状物可以螺旋包覆在箔(或聚酯膜)上来提供均一的厚度和终端-对-终端分布。此时，橡胶是未硫化的，因此是软的，混合在一起形成基本上无缝的层。再将橡胶硫化变硬并将表面研磨至规定的直径。
金属箔层222，任选的膜层223和硫化橡胶层216与心轴221紧密接触，这样可以进行机械加工而不会移动或松动。如果需要的话，再将形成的复合体用激光或其它合适的方法雕刻来得到复杂的设计和图案。例如，可以使用激光雕刻装置(未示出)在橡胶层216中切割穿孔或通孔218。激光束能完全切穿橡胶216来形成通孔218，但仅能部分切穿保护膜层223(如果使用的话)，并被箔层222反射。保持箔层222的完整性对于将完成的筛从多孔心轴221上移出是很重要的。此外，可以使用激光束在橡胶216的表面212上形成精密像差220，其原因如上所述。
当雕刻步骤完成时，从多孔心轴221上移出筛216。例如，向心轴内部施加空气压力。从多孔心轴中射出的空气压力使得所述筛足够膨胀而从心轴上滑落。这种心轴是印刷工业中已知的，其套筒具有不同的印刷图案，可以容易地调换。
一旦从心轴上移出，所述箔和任选的膜层可以去除并丢弃。如果有任何人工制造痕迹残留在所述筛的内部表面，可以通过刮削或研磨去除，从而得到光滑的内表面。
如上所述，本发明的成形筛与金属成形筛相比更好地适用于精密激光雕刻。术语“精密”表示具有X-Y维度且间距不大于约10.0密耳(254微米)的像差和/或凹陷，用来形成设计、图案或队列结构。在多个实施方式中，还希望单个像差和/或凹陷的Z方向几乎等于或稍大于其X-Y维度最窄宽度的至少约一半。Z方向的精密设计需要对于激光雕刻金属来说特别困难(如果可能的话)。
橡胶层对直接浇注方法中熔融聚合物的热不敏感，因此比常规塑料成形筛更适合这种应用。此外，橡胶层保护下覆塑料，因此所述筛也更适合在使用塑料筛技术的液压成形方法中使用。
支承层和橡胶层的厚度可以是任何具体应用中必需的或理想的厚度。但对于大部分膜成形应用来说，支承层通常比橡胶层厚。例如，当用作真空或液压成形方法的穿孔成形筛时，支承层的厚度约为500-3175微米，橡胶层的厚度约为500-1650微米。在优选的实施方式中，支承层的厚度约为1500微米，橡胶层的厚度约为1000微米。当成形筛中同时存在两层时，通常优选的比例为60％支承层对40％橡胶层。
成形筛的孔18、118(如果存在的话)可以是终端应用所需的任意尺寸和形状。例如，穿孔或孔18、118可以是圆形、六角形、椭圆形、卵形、五角形或其它所需的形状。此外，虽然在附图中标称的是垂直的，本领域技术人员应理解孔18、188可以相对于筛平面正切线以0-70度或更大的角度取向，如美国专利US 5562932；US 5718928所述，其公开内容通过引用并入本文。在卫生应用中，希望所述膜包含用于动态流体移动的大尺寸孔、或用于静态流体移动的毛细孔，或同时包含二者。所述大尺寸孔的平均直径为0.55mm-1.2mm，而毛细孔的直径为50-400微米。其间所有的范围也能用于在卫生应用中使用的有孔膜。其它的直径适合其它的应用。穿孔成形筛可以使用传统真空成形法或液压成形法来制造有孔成形膜。此外，本发明的成形筛在压花操作中是有用的，可以赋予膜或其它网状物纹理。
本文中公开的实施方式是示例性的，并不意于限制所附权利要求的范围。

Claims (22)

1.一种适合用于真空穿孔法或液压成形法来制备穿孔成形膜的穿孔成形筛，所述成形筛包含肖氏D硬度为46-60的热固性橡胶层，其中所述热固性橡胶层包括大量互相间隔的通孔开口，在所述互相间隔开口之间所述筛的外表面包括精密结构，所述精密结构具有X-Y维度且间距不大于10密耳。
2.如权利要求1所述的成形筛，其特征在于，所述穿孔成形筛具有内层和外层；所述外层通过粘合剂与所述内层粘结，其中所述外层是肖氏D硬度为46-60的热固性橡胶层；所述大量互相间隔的通孔开口还延伸通过所述内层。
3.如权利要求2所述的成形筛，其特征在于，所述内层选自塑料或金属。
4.如权利要求3所述的成形筛，其特征在于，所述内层是塑料，所述塑料选自：聚丙烯、聚酯、丙烯酸类树脂、聚氨酯、缩醛、聚碳酸酯、聚醚醚酮和其混合物或掺混物。
5.如权利要求4所述的成形筛，其特征在于，所述内层由缩醛树脂制成，所述热固性橡胶层选自硬橡胶或氢化丁腈橡胶。
6.如权利要求4所述的成形筛，其特征在于，所述内层用氰基丙烯酸酯粘合剂与所述橡胶层结合。
7.如权利要求3所述的成形筛，其特征在于，所述内层是金属，所述金属选自：冷轧钢、碳钢、不锈钢、有色金属、上述金属的任一种合金和其混合物。
8.如权利要求7所述的成形筛，其特征在于，所述有色金属选自铝、镍和铜。
9.如权利要求7所述的成形筛，其特征在于，所述内层由铝制成，所述热固性橡胶层选自硬橡胶或氢化丁腈橡胶。
10.如权利要求1所述的成形筛，其特征在于，所述热固性橡胶层包括天然的或合成的橡胶，所述橡胶选自：硫化的天然橡胶、氯丁橡胶、硅橡胶、氟弹性体、聚氨酯、乙烯丙烯二烯M-类橡胶、氢化丁腈橡胶和其混合物及掺混物。
11.如权利要求1所述的成形筛，其特征在于，所述热固性橡胶层还包含分散其中的热导材料。
12.一种制造成形筛的方法，所述方法依次包括以下步骤：将热固性橡胶材料施用于支承层以形成橡胶层，硫化所述热固性橡胶来生产肖氏D硬度为46-60的橡胶；在橡胶层和支承层中产生一系列通孔穿孔；以及在产生所述通孔穿孔之前或之后在所述热固性橡胶表面上产生精密结构，所述精密结构位于所述筛中的通孔穿孔之间；所述精密结构具有X-Y维度且间距不大于10密耳。
13.如权利要求12所述的方法，其特征在于，所述方法还包括将所述成形筛定形为圆柱体的步骤，所述圆柱体的外表面上带有橡胶。
14.如权利要求12所述的方法，其特征在于，在所述橡胶层与支承层结合之前将所述成形筛定形为圆柱体。
15.如权利要求12所述的方法，其特征在于，所述方法还包括激光雕刻所述成形筛的步骤，从而在其上形成表面像差。
16.如权利要求12所述的方法，其特征在于，所述支承层选自金属或塑料。
17.如权利要求16所述的方法，其特征在于，所述支承层包含选自聚丙烯、聚酯、丙烯酸类树脂、聚氨酯、缩醛、聚碳酸酯、聚醚醚酮或其混合物或掺混物的树脂。
18.如权利要求17所述的方法，其特征在于，所述支承层由缩醛树脂制成，所述热固性橡胶层选自硬橡胶或氢化丁腈橡胶。
19.如权利要求16所述的方法，其特征在于，所述支承层用氰基丙烯酸酯粘合剂与所述热固性橡胶层结合。
20.如权利要求12所述的方法，其特征在于，所述热固性橡胶层包括天然的或合成的橡胶，所述橡胶选自：硫化的天然橡胶、氯丁橡胶、硅橡胶、氟弹性体、聚氨酯、乙烯丙烯二烯M-类橡胶、氢化丁腈橡胶和其混合物及掺混物。
21.如权利要求12所述的方法，所述方法还依次包括以下步骤：将金属箔层施用在多孔心轴上；将所述热固性橡胶层和支承层施用在所述金属箔层上；在所述橡胶层和所述支承层中产生通孔穿孔，同时所述金属箔层保持未穿孔；向所述多孔心轴施加空气压力，从而将所述金属箔和橡胶层与所述多孔心轴分离；从所述多孔心轴上移出所述筛。
22.如权利要求21所述的方法，其特征在于，在所述金属层和所述橡胶层之间施用聚合物膜层，以防止橡胶与所述金属层粘结。
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