CN102348437B - 用于制造压花纤维网的方法 - Google Patents

用于制造压花纤维网的方法 Download PDF

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Publication number
CN102348437B
CN102348437B CN201080011364XA CN201080011364A CN102348437B CN 102348437 B CN102348437 B CN 102348437B CN 201080011364X A CN201080011364X A CN 201080011364XA CN 201080011364 A CN201080011364 A CN 201080011364A CN 102348437 B CN102348437 B CN 102348437B
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China
Prior art keywords
precursor web
shaped structure
embossing
discrete
microns
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Expired - Fee Related
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CN201080011364XA
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CN102348437A (zh
Inventor
B.F.格雷
K.J.斯通
C.H.范瓦尔肯伯格
R.G.科伊
S.B.格罗斯
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Procter and Gamble Co
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Procter and Gamble Co
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract

本发明公开了一种用于制造压花纤维网的方法。在成形结构和静压充气室之间提供前体纤维网。成形结构具有多个离散的突出元件。通过静压充气室提供压力抵靠前体纤维网和成形结构以使前体纤维网适形于成形结构的离散的突出元件来成形压花纤维网。所得的压花纤维网具有多个包括开口近端的离散的延伸元件。

Description

用于制造压花纤维网的方法
发明领域
本发明涉及用于制造包括多个离散的延伸元件的压花纤维网的方法。
发明背景
材料纤维网诸如热塑性薄膜具有多种用途，包括用作吸收制品的组件材料(诸如顶片和底片)、包装(诸如流动包裹、收缩包装膜和塑料袋)、垃圾袋、食品包裹物、牙线、擦拭物、电子元件等。就材料纤维网的这些用途中的许多而言，可有益地使材料纤维网具有纹理化表面，所述纹理化表面可为材料纤维网的表面提供所期望的触觉印象、视觉印象和/或听觉印象。
表现出柔软且丝般触觉印象的聚合物纤维网可通过真空成形法或液压成形法来制造。在典型的真空成形法中，将前体纤维网加热并放置到成形结构上。然后真空迫使前体纤维网适形于成形结构的纹理。取决于成形结构的纹理和适形程度，所得的聚合物纤维网具有可提供柔软且丝般触觉印象的纹理。尽管真空成形法可适用于制造柔软且丝般聚合物纤维网，但真空成形法通常受到与能够施加到前体纤维网上的压力大小相关的限制。因此，通常需要在放置到成形结构上之前加热前体薄膜以显著地软化或熔融前体薄膜以便将前体薄膜真空成形到成形结构上。由于加热步骤和由所述方法产生的有限压力的缘故，真空成形法因此在所述方法可执行速度方面是一种低效率的方法。
在典型的液压成形法中，将前体纤维网放置到成形结构上，并且高压和高温喷水迫使前体纤维网适形于成形结构的纹理。取决于成形结构的纹理，所得的聚合物纤维网可具有可提供柔软且丝般触觉印象的纹理。液压成形法虽然能够生产出柔软且丝般的聚合物纤维网，但其通常为一种涉及到使用高压和高温喷水和后续干燥步骤(包括脱水步骤)的高成本且低效率的方法。
压花为一种如下的方法，其通常涉及对基底进行机械加工以导致基底在压力下适形于雕刻在或以其他方式形成在压花辊上的图案的深度和轮廓。所述方法被广泛地用于消费品的生产中。制造商们使用压花方法向产品中赋予纹理或浮雕图案，所述产品由纺织物、纸材、合成材料、塑性材料、金属和木材制成。
压花方法已被用来向聚合物薄膜提供纹理。然而，此类压花方法通常需要将熔融树脂挤出到成形结构上，或在放置到成形结构上之前加热前体纤维网，然后进行压花以生产出压花纤维网。然后冷却压花纤维网，通常通过冷却用来压花加热过的前体纤维网或熔融树脂的压花辊或板来冷却。所述冷却步骤常常用来定形压花纤维网中的纹理。然而，这些加热步骤和冷却步骤为所述方法增加了不可取的成本和低效率以及复杂程度。此外，此类压花方法通常还涉及到相对长的保压时间，这可导致缓慢低效的方法。
使用常规的压花方法通常也难以赋予前体纤维网相对小尺度的纹理。此外，典型的压花方法还趋于生产出在整个纤维网中具有相对均匀厚度的压花纤维网。
例如，美国专利5,972,280公开了一种压花方法，该方法利用压花辊的热雕刻表面和在腔室内部所施加的静压来加热纤维网并使它在压花辊的表面上变形。这种方法采用通常处在纤维网的软化温度以上的高温和约0.007MPa至约0.7MPa的较低压力。因此，压花图案因设置在纤维网的单面上的刻痕而成形而不影响纤维网的相对表面。
尽管存在本领域的认识，但仍然期望开发出一种更高效的用于制造压花纤维网的方法，所述纤维网具有所期望的触觉印象、视觉印象和/或听觉印象，尤其是压花纤维网在压花纤维网的所期望的区域中表现出薄化。在某些方面，一种期望的方法就所述方法所需要的能量和资源而言是高效的。在某些方面，一种期望的方法能够高速地运行。在某些方面，一种期望的方法能够在相对低的温度诸如环境温度下运行。
发明概述
在一个实施方案中，一种用于制造压花纤维网的方法包括将前体纤维网在静态气压充气室和具有多个离散的突起元件的成形结构之间喂入。所述方法还包括从静态气压室施加压力顶靠与成形结构相对的前体纤维网，从而产生横跨前体纤维网的足以使前体纤维网适形于成形结构的离散的突出元件压差以形成包括具有开口近端的多个离散的延伸元件的压花纤维网。
对于本领域的技术人员来讲，通过阅读以下结合附图所作的发明详述、实施例和所附权利要求，发明的附加特征可变得显而易见。
附图简述
图1是根据本公开的一个实施方案的成形结构的一部分的透视图；
图2是图1所示的成形结构的一部分的放大透视图；
图3为根据本公开的一个实施方案的成形结构的顶视图；
图4为根据本公开的一个实施方案的成形结构的突出元件的侧视图；
图5为显示根据本公开的一个实施方案的成形结构的侧视图的显微照片；
图6为通过根据本公开的一个实施方案的方法所形成的压花纤维网的一部分的透视图；
图7为通过根据本公开的一个实施方案的方法所形成的压花纤维网的一部分的剖面图；
图8为通过根据本公开的一个实施方案的方法所形成的压花纤维网的一部分的透视图，所述部分具有包括开口远端的离散的延伸元件；
图9为根据本公开的一个实施方案的方法的示意图，其示出了静态气压室；
图10A为通过根据本公开的一个实施方案的方法所形成的压花纤维网的显微照片底视图；并且
图10B为通过根据本公开的一个实施方案的方法所形成的压花纤维网的显微照片底视图。
虽然在说明书之后提供了特别指出和清楚地要求保护本发明的权利要求书，但是据信通过下面的描述并结合附图可以更充分地理解本发明。为了更清楚地显示其它元件，某些附图可通过省略选择的元件进行简化。在任何示例性实施方案中，除了在相应的文字说明书明白无误地描述之外，某些附图中元件的此类省略并不一定代表具体元件的存在或不存在。附图中没有一个是必定按比例绘制的。
发明详述
本文公开了一种用于形成压花纤维网的方法，所述方法克服了前述现有技术的缺点中的一个或多个。具体地讲，该方法的实施方案现在使一种更高效的纤维网压花方法成为可能。例如，该方法的实施方案现在能够赋予纤维网相对小尺度的纹理。此外，该方法的实施方案现在还能够避免现有技术所需的麻烦的加热步骤和冷却步骤。此外，该方法的实施方案也不需要现有技术的方法所需要的长保压时间。此外，与现有技术静态压力法相比，该方法的各实施方案可允许形成具有开口近端和开口或闭合远端的三维离散的延伸元件。在某些实施方案中，该方法可用来形成可用作例如包装材料诸如气泡膜的宏观尺度的结构。
该方法一般包括将前体纤维网在静压充气室和成形结构之间喂入。成形结构包括多个离散的突出元件。该方法还包括从静压充气室施加足以使前体纤维网适形于成形结构的离散的突出元件的压力顶靠前体纤维网和成形结构，以形成包括具有开口近端的多个离散的延伸元件的压花纤维网。下面更进一步详细地描述了该方法的这些方面。
成形结构
可用于本发明的方法的成形结构包括多个离散的突出元件和完全围绕着所述离散的突出元件的平面。本发明的成形结构的离散的突出元件按照比例相对于在压花方法中用在模具上的典型图案要小。成形结构的离散的突出元件也具有较高的纵横比。这种特性组合可允许本发明的所述方法生产包括具有薄化远端的较高纵横比的延伸元件的压花纤维网，甚至不用加热前体纤维网乃至以高速生产。
本发明的成形结构(例如针对图1所提到的成形结构8)用于制造本发明的方法中的压花纤维网。成形结构有时候被称为成形筛网。图1在局部透视图中显示本发明的成形结构8的一部分。图1的离散的突出元件10从成形结构第一表面12伸出具有于大致柱形的柱状形状。
图2是图1所示成形结构8的进一步放大的局部透视图，并且与图7中的压花纤维网18的类似视图相比较。离散的突出元件10可用下面所描述的方法制造以从第一表面12延伸到远端14。如图2所示，离散的突出元件10可具有从相邻突出之间的第一表面12至远端14所测得的最小振幅测得的高度(“hp”)。同样，第一表面12构成完全围绕着离散的突出元件10的平面区域。突出元件高度可为至少约30微米，至少约50微米，至少约75微米，至少约100微米，至少约150微米，至少约250微米，或者至少约380微米。突出元件10具有直径(“dp”)；对于大致圆柱形的结构，其为外直径。对于突出元件10的非均匀的横截面和/或非圆柱形结构，直径dp被测量为在突出元件10的1/2高度hp处的突出元件的平均横截面尺寸，如图2所示。突出元件可具有可为约10微米至约5,000微米的直径。其它合适的直径包括例如约50微米至约500微米，约65微米至约300微米，约75微米至约200微米，约100微米至约25,000微米，约500微米至约5000微米，或约800微米至约2,500微米的直径。在某些实施方案中，突出元件可具有较大的直径用于成形宏尺度离散的延伸元件。例如，突出元件可具有至多约2.5厘米，至多约2厘米，至多约1.5厘米，至多约1cm，至多约0.5厘米，或至多约0.1厘米的直径。在一个实施方案中，成形结构的突出元件将具有小于约500微米或小于约300微米的直径。
对于每个突出元件10，可确定定义为hp/dp的突出元件纵横比。突出元件10可具有至少约0.5，至少约0.75，至少约1，至少约1.5，至少约2，至少约2.5，或至少约3或更高的纵横比hp/dp。突出元件10可具有在两个相邻的突出元件10之间的中心至中心间距Cp，其为约100微米至约1,020微米，为约100微米至约640微米，为约150微米至约500微米，或为约180微米至约430微米。
一般来讲，据信两个相邻突出元件10之间的实际距离(即，边缘至边缘尺寸)应当大于前体纤维网厚度t的二倍以确保前体纤维网在相邻突出元件10之间的变形合适。离散的突出元件10通常将具有约30微米至约800微米，约30微米至约650微米，约50微米至约500微米，或者约60至约300微米的边缘至边缘间距。
一般来讲，本发明的成形结构对于成形结构的给定部分而言将包括至少约95个离散的突出元件每平方厘米，至少约240个离散的突出元件每平方厘米，约350至约10,000个离散的突出元件每平方厘米，约500至约5,000个离散的突出元件每平方厘米，或者约700至约3,000个离散的突出元件每平方厘米。
在某些实施方案中，成形结构的给定部分可包括如在前面段落中所述的离散的突出元件的面密度，并且成形结构的其它部分根本不包括离散的突出元件。在其它实施方案中，成形结构的离散的突出元件可位于成形结构的不同水平面上。
一般来讲，因为每个单独的突出元件10的实际高度hp可变化，多个突出元件10的平均高度(“hpavg”)可通过确定在成形结构8的预定面积上的突出元件平均最小幅度(“Apmin”)和突出元件平均最大幅度(“Apmax”)而确定。类似地，对于变横截面尺寸，可对于多个突出8确定平均突出直径(“dpavg”)。此类振幅和其他尺寸的测量可通过本领域已知的任何方法诸如计算机辅助扫描显微术和相关数据处理来进行。因此，对于成形结构8的预设部分而言，突出元件10的平均纵横比(“ARpavg”)可表示成hpavg//dpavg。突出元件10的尺寸hp和dp可根据用于制造成形结构8的已知技术规范间接地确定，如下面更全面公开的那样。
在一个实施方案中，离散的突出元件的平均高度hpavg对前体纤维网的厚度的比率为至少约1∶1，至少约2∶1，至少约3∶1，至少约4∶1，或者至少约5∶1。这个比率对确保前体纤维网被足够拉伸以便它变成永久变形来生产本发明的压花纤维网是重要的，尤其是在所期望的工艺条件和速度下。
图3是本发明的成形结构的一个实施方案的顶视图。成形结构包括完全被平面区域16围绕的多个离散的突出元件10。
成形结构的离散的突出元件可具有远端，它们可为平直的、圆形的或尖锐的，这取决于是否希望它生产具有带开口(在成形结构上要求较尖锐的突出元件)或闭合(在成形结构上要求更圆形的突出元件)远端的延伸元件的压花纤维网。成形结构的离散的突出元件的圆形远端可具有某个尖端半径，例如为约5微米至约150微米，约10微米至约100微米，约20微米至约75微米，或者约30微米至约60微米。
离散的突出元件的侧壁可为完全直立的或者可为锥形的。在一个实施方案中，离散的突出元件具有锥形侧壁，因为锥形侧壁可允许纤维网在压花后更容易地与成形结构分离。在一个实施方案中，侧壁通常将具有约0°至约50°，约2°至约30°，或者约5°至约25°的锥度。
图4显示成形构件8的离散的突出元件10的一个实施方案的剖面图，其中离散的突出元件10的圆形远端14具有约46微米(0.0018英寸)的尖端半径。离散的突出元件10的侧壁具有约11°的锥度。
图5是包括具有如图4所描述的尺寸的多个离散的突出元件的成形结构的显微照片。
在一个实施方案中，突出元件10的直径是恒定的或者随着振幅增大而减小。如图2所示，例如，突出元件10的直径或最大的横向截面尺寸靠近第一表面12最大并且稳固地减小到远端14。这种结构据信对帮助确保压花纤维网可从成形结构8容易地移除是令人满意的。
成形结构的离散的突出元件可包括多种不同的横截面形状，例如大致圆柱形的或非圆柱形性的形状，包括圆形、椭圆形、正方形、三角形、六方形、梯形、脊形、金字塔形、雪人、蘑菇、球形、砂漏形等以及它们的组合。
成形结构8可由可进行成形的任何材料制成以让突出元件10具有所需的尺寸来制造本发明的压花纤维网，它在成形结构8所经历的工艺温度范围内是尺寸上稳定的，具有至少约30MPa，至少约100MPa，至少约200MPa，至少约400MPa，至少约1,000MPa，或者至少约2,000MPa的拉伸模量；至少约2MPa，至少约5MPa，至少约10MPa，或者至少约15MPa的屈服强度；和至少约1％，至少约5％，或者至少约10％的断裂应变。已发现随着成形结构的材料模量增加，较高的高纵横比突出元件形成较好的压花纤维网，只要它具有足够的断裂应变(即，不太脆)以便不断裂。对于模量和屈服强度数据，可依照已知的方法通过测试确定数值，并可以100％/分钟的应变速率在标准的TAPPI条件下进行测试。
在一个实施方案中，突出元件10与成形结构8整体制成。就是说，或是通过移除材料或是通过装配材料作为一个整体结构制造成形结构。例如，具有所需的相对小尺度的突出元件10的成形结构8可通过以如下方式局部选择性地除去材料来制造：诸如通过化学蚀刻、机械蚀刻，或通过使用高能量源诸如放电机(EDM)或激光来消融，或通过电子束(e束)，或通过电化学加工(ECM)。在一个实施方案中，成形结构一般可根据美国专利4,342,314的教导通过光蚀刻层压方法来构造。
在制造成形结构8的一种方法中，易于激光改性的基体材料被激光“蚀刻”以选择性地移除材料来形成突出元件10。所谓“易于激光改性的”是指所述材料可通过激光以可控制的方式选择性地被移除，要认识到，在激光方法中所用光线的波长以及功率水平可需要与材料相匹配(或反之亦然)以便结果最优。激光蚀刻可通过已知的激光技术来实现，选择必要的波长、功率和时间参数以生产出所述期望的突起元件尺寸。目前已知的易于激光改性的材料包括热塑性塑料诸如聚丙烯、乙缩醛树脂诸如源自DuPont(WilmingtonDE，USA)的
Figure BDA0000090645340000071
热固性塑料诸如交联聚酯、或环氧化物、乃至金属诸如铝、铜、黄铜、镍、不锈钢、或它们的合金。任选地，热塑性和热固性材料可充满颗粒或纤维填充料以增强对于某些光波长的激光的相容性和/或改善模量或韧性以制造更耐用的突出元件10。例如，某些聚合物例如PEEK可通过用足够数量的中空碳纳米管纤维均匀填充聚合物以较高分辨率和以较高的速度进行激光加工。
在一个实施方案中，成形结构可以连续方法进行激光加工。例如，可将聚合材料诸如
Figure BDA0000090645340000081
提供为圆柱形形式以作为基体材料，所述基体材料具有中心纵向轴线、外表面和内表面，所述外表面和内表面限定基体材料的厚度。也可将其提供为实心辊。活动激光源可大致正交于所述外表面指向。所述活动激光源可在某个方向上平行于基体材料的中心纵向轴线移动。所述圆柱形基体材料可围绕中心纵向轴线旋转，同时激光源加工或蚀刻基体材料的外表面以按某种图案除去基体材料的选定部分，所述图案限定多个离散的突出元件。每个突出元件可各具有大致圆柱形的和柱状形状，如本文所公开的那样。通过当圆柱形基体材料转动时平行于圆柱形基体材料的纵向轴线移动激光源，可协调相对运动即转动和激光运动使得当圆柱形基体材料的每次完全转动时，突出元件的预定图案可类似于螺栓的“螺纹”以连续方法被成形。
本发明的成形结构可为如下形式：平板、辊、带、套管等。在一个实施方案中，成形结构为辊的形式。
成形结构的底部表面可为例如多孔的或无孔的。例如，底部表面可包括开口，开口具有足够小的宽度以便前体纤维网不会变形进入开口中，开口通过允许空气通过成形结构给成形结构通风。在一个实施方案中，提供了一个部件以允许所捕集的任何空气在纤维网下方逸出。例如，可提供真空辅助来在纤维网下方移除空气，例如通过使空气通过成形结构中的排气孔，以便不增大生产压花纤维网所需要的必需压力。
成形结构的底部表面可为例如多孔的或无孔的。例如，底部表面可包括开口，开口具有足够小的宽度以便前体纤维网不变形进入开口中，开口通过允许空气通过成形结构给成形结构通风。在一个实施方案中，提供了一个部件以允许所捕获的任何空气在纤维网下方逸出。例如，可提供真空辅助来在纤维网下方移除空气，例如通过使空气通过成形结构中的排气孔，以便不增大生产压花纤维网所需要的必需压力。
本发明的成形结构任选地还可包括凹痕或孔。如果成形结构还包括凹痕或孔，当与本发明的一种方法中的静压充气室结合使用时，前体纤维网可被静压充气室迫使进入成形结构的凹痕或孔中，使得离散的延伸元件可在前体纤维网中成形，从前体纤维网与其中成形结构的突出元件由其成形离散的突出元件的表面相对的表面伸出。因此，可生产两侧压花的纤维网，在压花纤维网的每侧上具有不同的延伸元件的图案或尺寸。取决于在成形结构和静压充气室之间所生成的压力以及突出元件的几何形状和任选的成形结构的凹痕或孔，压花纤维网的离散的延伸元件可具有闭合或开口远端。
静压充气室
参见图9，利用静压充气室36来提供顶靠前体纤维网34的力以使前体纤维网34适形于成形结构8的离散的突出元件10。优选地，静压充气室36为静态气压室。气体可为空气、氮气、二氧化碳等、或它们的组合。
静态气压室36在前体纤维网34上施加压力。静态气压室36可包括限定与前体纤维网34相邻的充气室40的罩38。罩38可包括至少一个高压气体入口42，以允许高压气体或其它流体进入罩38，从而产生静压条件。在静态气压条件下，没有速度和密度冲击在未压花的前体纤维网34上，与动压源例如气刀一样。恰恰相反，在罩38中保持静态高气压，其在前体纤维网34的面向静压充气室36表面和前体纤维网34的面向成形结构8表面之间产生横跨前体纤维网的压差。在一个实施方案中，罩38可宽于前体纤维网，前体纤维网可增强与罩38所形成的密封。压差足以迫使前体纤维网34适形于成形结构8的离散的突出元件10。压差可例如通过在前体纤维网34的面向成形结构8的表面上施用真空而增强。
适用的静态气压室也描述于2010年3月11日提交的题目为“APPARATUS FOR EMBOSSING A WEB”的美国临时专利申请序列号____/____，____(P&G Case 11639P)中，以及描述于美国专利5,972,280中。
前体纤维网
根据本公开的方法将前体纤维网34转换加工成压花纤维网16。适用的前体纤维网包括可由横跨前体纤维网34的静压充气室36生成的压差进行变形的材料，使得前体纤维网34适形于成形结构8的离散的突出元件10以生产压花纤维网16。
前体纤维网34通常包括合成材料、金属材料、生物材料(具体地讲，动物衍生材料)、或它们的组合。前体纤维网34可任选地包括纤维素材料。在一个实施方案中，前体纤维网34不含纤维素材料。适用前体纤维网的非限制性实例包括薄膜例如聚合物或热塑性薄膜、箔例如金属箔(例如，铝、黄铜、铜等)、包括供应充足的聚合物的纤维网、泡沫、包括纤维的(例如，
Figure BDA0000090645340000101
的纤维质非织造纤维网、胶原薄膜、丁聚糖膜、人造丝、玻璃纸等。合适的前体纤维网还包括这些材料的层压体或共混物。
如果所述前体为纤维网，则所述纤维网通常将具有高密度使得其行为类似于薄膜材料。这种高密度纤维网的一个实例为
Figure BDA0000090645340000102
在一个实施方案中，前体纤维网34为聚合物薄膜。合适的聚合物薄膜包括热塑性薄膜诸如聚乙烯、聚丙烯、聚苯乙烯、聚对苯二甲酸乙二酯(PET)、聚甲基丙烯酸甲酯(PMMA)、聚乙烯醇(PVA)、尼龙、聚四氟乙烯(PTFE)(例如，特氟隆)、或它们的组合。合适的聚合物薄膜可包括聚合物的共混物或混合物。
在某些实施方案中，前体纤维网34可为纤维网，所述纤维网包括供应充足的聚合物诸如聚交酯、聚乙交酯、聚羟基链烷酸酯、多糖、聚己酸内酯等、或它们的混合物。
压花之前的前体纤维网34的厚度通常将在约5至约300微米，约5微米至约150微米，约5微米至约100微米，或约15微米至约50微米的范围内。其它合适的厚度包括约1、2、3、4、5、6、7、8、9、10、20、30、40、50、60、70、80、90、100、150、200、250或300微米。
前体纤维网诸如聚合物纤维网通常将具有约-100℃至约120℃，或约-80℃至约100℃，或其他合适范围内的玻璃化转变温度。前体纤维网诸如聚合物纤维网可具有约100℃至约350℃的熔点。例如，由LDPE或者LDPE和LLDPE的共混物形成的前体纤维网34具有约110℃至约122°的熔点。由聚丙烯形成的前体纤维网34具有约165℃的熔点。由聚酯形成的前体纤维网34具有约255℃的熔点。由尼龙6形成的前体纤维网34具有约21 5℃的熔点。由PTFE形成的前体纤维网34具有约327℃的熔点。
在一个实施方案中，该方法在小于前体纤维网的熔点的温度下进行。例如，该方法可在比前体纤维网的熔点低10℃的温度下进行。在另一个实施方案中，该方法在大体上等于前体纤维网的熔点的温度下进行。在一个实施方案中，该方法在大于前体纤维网的玻璃化转变温度的温度下进行。
任选地，在该方法中，在压花之前可增塑前体纤维网34以使其脆性减小。
在一个实施方案中，前体纤维网34是应变硬化的。前体纤维网34的应变硬化性质可为所期望的以有利于前体纤维网34适形于成形结构8的离散的突出元件10。这对于生产其中期望压花纤维网16的延伸元件22的闭合远端24的压花纤维网可为优选的。
前体纤维网34可为具有足够的材料特性以通过本公开的压花方法成为本文所述的压花纤维网16的任何材料例如聚合物膜。前体纤维网34通常将具有屈服点并且前体纤维网34优选地被拉伸超过其屈服点以形成压花纤维网16。就是说，前体纤维网34应当具有足够的屈服特性，使得前体纤维网34可应变到某一程度而不破裂以生产具有闭合远端24的预期的离散的延伸元件22，或者在压花纤维网16包括具有开口远端24的离散的延伸元件22的情况下破裂形成开口远端24。如下面所公开的那样，加工条件例如温度对于给定的聚合物可变化以允许它伸展而破裂或不破裂来形成具有所期望的离散延伸元件22的压花纤维16。因此，一般来讲，已发现被用作用于生产压花纤维网16的前体纤维网34的原材料表现出低屈服和高延伸率特性。此外，如前所述，前体纤维网优选地应变硬化。适于用作前体纤维网34的薄膜的实例包括包含如下物质的薄膜：低密度聚乙烯(LDPE)、线性低密度聚乙烯(LLDPE)、以及线性低密度聚乙烯和低密度聚乙烯的共混物(LLDPE/LDPE)。
前体纤维网34也必须为可充分变形的并具有足够的用作前体纤维网34的延展性。如本文所用，术语“可变形的”描述如下的材料：当被拉伸超过其弹性极限时，所述材料将大体上保持其新形成的构象，并且在或靠近所得压花纤维网16的离散的延伸元件22的远端24和/或沿着其侧壁表现出薄化。
一种被发现适于用作前体纤维网34的材料为得自The Dow ChemicalCompany(Midland，MI，USA)的DOWLEX 2045A聚乙烯树脂。具有20微米厚度的这种材料的薄膜可具有至少12MPa的拉伸屈服强度；至少53MPa的极限拉伸强度；至少635％的极限伸长率；和至少210MPa的拉伸模量(2％正割)(以上测量值每个均根据ASTM D 882确定)。其它合适的前体纤维网包括得自RKW US，Inc.(Rome，Georgia)的约25微米(1.0mil)厚且具有约24克/平方米(“gsm”)的基重的聚乙烯薄膜以及得自RKW US，Inc.的具有约14gsm的基重和约15微米厚度的聚乙烯/聚丙烯薄膜。
前体纤维网34可为两个或更多个纤维网的层压体，并且可为共挤出的层压体。例如，前体纤维网34可包括两个层，并且前体纤维网34可包括三个层，其中最内层被称为芯层，并且所述两个最外层被称为表皮层。在一个实施方案中，前体纤维网34包括具有约25微米(0.001英寸)总体厚度的三层共挤出层压体，其中芯层具有约18微米(0.0007英寸)的厚度；以及每个表皮层具有约3.5微米(0.00015英寸)的厚度。在一个实施方案中，这些层可包括具有不同应力/应变和/或弹性特性的聚合物。
前体纤维网34可使用在常规共挤出薄膜制造设备上生产多层的薄膜的常规规程来制造。如果需要包括共混物的层，可首先干共混上述各组分的粒料，然后在喂入该层的挤出机中进行熔融混合。作为另外一种选择，如果在挤出机中发生了不充分混合，则可首先干燥共混所述粒料，然后在预配混挤出机中进行熔融混合，随后在薄膜挤出之前重新制粒。用于制造前体纤维网34的合适的方法公开于美国专利5,520,875和美国专利6,228,462中。
一般来讲，在压花纤维网16上形成高面密度(或低平均中心至中心间距)的离散的延伸元件22的能力会受到前体纤维网34的厚度的限制。
在某些实施方案中，前体纤维网34还可任选地包括表面活性剂。如果利用的话，优选的表面活性剂包括来自非离子族的那些例如：醇乙氧基化物、烷基酚乙氧基化物、羧酸酯、甘油酯、脂肪酸的聚氧乙烯酯、与松香酸相关的脂族羧酸的聚氧乙烯酯、脱水山梨醇酯、乙氧基化脱水山梨醇酯、乙氧基化天然脂肪、油、和蜡、脂肪酸的乙二醇酯、羧基氨化物、二乙醇胺缩合物、和聚环氧烷嵌段共聚物。所选定的表面活性剂的分子量可在约200克/摩尔至约10,000克/摩尔的范围内。优选的表面活性剂具有约300至约1,000克/摩尔的分子量。
如果利用的话，最初混合进前体纤维网34中的表面活性剂含量按总的前体纤维网34重量计可多达10％。在优选的分子量范围(300-1,000克/摩尔)中的表面活性剂可以较低含量进行添加，一般为整个前体纤维网34重量的约5％或以下。
在某些实施方案中，前体纤维网34也可在所述共混聚合物中包括二氧化钛。可提供二氧化钛以便增大压花纤维网16的不透明度。二氧化钛可按前体纤维网34例如低密度聚乙烯的重量计至多约10％的量加入。
任选地，可在前体纤维网34的一个或多个层中加入其它添加剂诸如颗粒材料例如颗粒状皮肤处理剂或防护剂，或者吸收气味活性添加剂例如沸石。在一些实施方案中，当用于皮肤接触应用时，包括颗粒物质的压花纤维网可允许活性物质以非常直接和有效的方式接触皮肤。具体地讲，在一些实施方案中，离散的延伸元件22的形成可在或靠近它们的远端24暴露颗粒物质。因此，活性物质诸如皮肤护理剂可局限在或靠近离散的延伸元件22的远端24以允许当压花纤维网16用于皮肤接触应用时皮肤直接接触到此类皮肤护理剂。
如果用于前体纤维网34，则颗粒物质的平均粒度通常将为0.2至约200微米或者约5微米至约100微米。使用某些颗粒材料诸如云母干涉颗粒可显著地改善压花纤维网16的视觉外观。
前体纤维网34也可任选地包括用来向材料赋予某种颜色的着色剂诸如颜料、色淀、调色剂、染料、墨或其他试剂，以改善压花纤维网16的视觉外观。
本文合适的颜料包括无机颜料、珠光颜料、干涉颜料等。合适的颜料的非限制性实例包括滑石、云母、碳酸镁、碳酸钙、硅酸镁类、硅酸铝镁盐、二氧化硅、二氧化钛、氧化锌、红氧化铁、黄氧化铁、黑氧化铁、炭黑、群青颜料、聚乙烯粉末，甲基丙烯酸酯粉末，聚苯乙烯粉末，丝粉、结晶纤维素、淀粉、钛酸云母、氧化铁钛酸云母、氯氧化铋等。
合适的着色纤维网描述于2010年3月11日提交的题目为“COLOREDWEB MATERIAL COMPRISING A PLURALITY OF DISCRETE EXTENDEDELEMENTS”(P&G案号11634)的共同未决的美国专利申请序列号____/____，____、和2010年3月11日提交的题目为“WEB MATERIAL EXHIBITINGVIEWING-ANGLE DEPENDENT COLOR AND COMPRISING APLURALITY OF DISCRETE EXTENDED ELEMENTS”(P&G案号11635)的美国专利申请序列号____/____，____中。
前体纤维网34也可任选地包括填料、增塑剂等。
压花纤维网
前体纤维网34根据本公开的方法来加工以形成压花纤维网16，所述压花纤维网可具有各种所期望的结构特征和特性诸如所期望的柔软手感和审美上悦人的视觉外观。前体纤维网34被设置在成形结构8和所提供的静压充气室36之间以使前体纤维网34适形于成形结构8的离散的突出元件10。参见图6，从而产生了具有离散的延伸元件22的压花纤维网16。如图7所示，离散的延伸元件22具有开口近端30和开口(如图8所示)或闭合远端24(如图6和7所示)
在一个实施方案中，通过本文所述的方法得到的压花纤维网16可具有类似于美国专利7,402,723或7,521,588所详述的结构10。
所述三维的压花纤维网16从前体纤维网34生产出，所述前体纤维网可为单层的材料纤维网或多层的共挤出的或层压材料纤维网，如前文所述。层压薄膜材料可为共挤出的，如本领域已知的用于制造层压薄膜的材料，包括具有表皮层的薄膜。在图6所示的实施方案中，前体纤维网34为两层的层压薄膜，所述薄膜包括第一层18和第二层20。
离散的延伸元件22被成形为纤维网的突起延伸部，一般位于其第一表面26上。压花纤维网16上的离散的延伸元件22的数目、尺寸和分配情况可基于所期望的柔软感、声音效应和视觉效应来预定。为在一次性吸收制品或包装中应用例如顶片、底片或纺粘纸包装材料，期望离散的延伸元件22仅从压花纤维网16的一个表面突出。因此，当将压花纤维网16用作一次性吸收制品中的顶片时，可定向压花纤维网16使得离散的延伸元件22接触皮肤给予优良的柔软印象。此外，具有包括闭合远端24的离散的延伸元件22还可导致回渗减少，即，减少在首次穿过了顶片的孔达到下面的吸收层之后被再引入到顶片的表面中的流体的量。
参见图7，离散的延伸元件22可被描述成从压花纤维网16的第一表面28突出。同样，离散的延伸元件22可被描述成与前体纤维网34成一整体，并通过前体纤维网34的永久局部塑性变形而形成。离散的延伸元件22可被描述成具有限定敞开的近侧部分30和闭合或开口远端24的侧壁28。离散的延伸元件22各具有从相邻的延伸元件之间的最小振幅Amin至在闭合或敞开的远端24处的最大振幅Amax测得的高度h。离散的延伸元件22具有直径d，对于大致圆柱形结构10而言，其为在横向截面处的外直径。“横向”是指大致平行于第一表面26的平面。就具有非均匀横向截面的大致柱状离散的延伸元件22和/或非圆柱形结构的离散的延伸元件22而言，直径d被测量为离散的延伸元件的1/2高度h处的平均横向截面尺寸。因此，对于每个离散的延伸元件，可确定被定义为h/d的纵横比。离散的延伸元件可具有至少约0.2，至少约0.3，至少约0.5，至少约0.75，至少约1，至少约1.5，至少约2，至少约2.5，或者至少约3的纵横比h/d.离散的延伸元件22通常将具有至少约30微米，至少约50微米，至少约65微米，至少约80微米，至少约100微米，至少约120微米，至少约150微米，或者至少约200微米的高度h。延伸元件通常将具有与前体纤维网的厚度至少相同的高度，或至少2倍的前体纤维网的厚度，或优选地至少3倍的前体纤维网的厚度的高度。离散的延伸元件22通常将具有约50微米至约5,000微米，约50微米至约3,000微米，约50微米至约500微米，约65微米至约300微米，或约75微米至约200微米的直径d。在某些实施方案中，离散的延伸元件22可具有至多约2.5厘米，至多约2厘米，至多约1.5厘米，至多约1cm，至多约0.5厘米，或者至多约0.1厘米的较大的直径d。
就具有大致非柱状或不规则形状的离散的延伸元件22而言，离散的延伸元件的直径可被限定为两倍的离散的延伸元件在1/2高度处的回转半径。
就具有形状诸如脊的离散的延伸元件而言，所述脊在整个材料纤维网上纵向地延伸使得延伸元件具有开口的延伸元件的侧壁的一部分，离散的延伸元件的直径可被限定为延伸元件在1/2高度处的两个相对侧壁之间的平均最小宽度。
一般来讲，由于任何单个离散的延伸元件的实际高度h可能难以确定，并且由于实际高度可有变化，因此多个离散的延伸元件22的平均高度havg可通过确定压花纤维网16的预定区域上的平均最小振幅Amin和平均最大振幅Amax来确定。此类平均高度hpavg通常将落在上述高度范围内。类似地，对于变横截面尺寸，可确定多个离散的延伸元件22的平均直径davg。此类平均直径davg通常将落在上述直径范围内。此类振幅和其他尺寸的测量可通过本领域已知的任何方法，诸如通过计算机辅助扫描显微术和数据处理来进行。因此，压花纤维网16的预定部分上的离散的延伸元件22的平均纵横比ARavg可被表示为havg//davg。
在一个实施方案中，离散的延伸元件的直径为恒定的或随着振幅的增加而减小(振幅在闭合远端或开口远端24处增加至最大值)。离散的延伸元件22的直径或平均横向截面尺寸在近侧部分可为最大，并且横向截面尺寸稳固地减小至远端。这种结构10据信有助于确保压花纤维网16可从成形结构8容易地移除。在另一个实施方案中，离散的延伸元件22的直径随着振幅的增大而增大。例如，离散的延伸元件22可具有蘑菇形状。
前体纤维网34的薄化可由于所要求的形成高纵横比离散的延伸元件22的较深冲压而发生。例如，在闭合或开口远端24处和/或沿着侧壁可观察到薄化。所谓“观察到”是指当在放大的横截面上观察时薄化是明显的。此类薄化可为有益的，因为当触摸时，薄化的部分对压缩或剪切提供极小的阻力。例如，当一个人在表现出离散的延展元件22的侧面上接触压花纤维网16时，人的指尖首先接触离散的延展元件22的闭合或开口远端24。由于离散的延展元件22的高纵横比以及远端24处和/或沿着侧壁前体纤维网34的壁减薄的缘故，离散的延伸元件22提供对由人的手指施加在压花纤维网16上的压缩或剪切的很小阻力。这种阻力不足表现为柔软感，非常类似于丝绒织物的触感。
在闭合或开口远端24处和/或沿着侧壁前体纤维网34的薄化可相对于前体纤维网34的厚度或者相对于完全围绕着压花纤维网16的离散的延伸元件22的平面区域的厚度进行测量。前体纤维网34通常将表现出相对于前体纤维网34的厚度至少约25％，至少约50％，或者至少约75％的减薄。前体纤维网34通常将表现出相对于围绕着压花纤维网16的离散的延伸元件22的平面区域的厚度至少约25％，至少约50％，至少约75％，或者至少约85％的减薄。
应当指出的是，仅具有如本文所公开的离散的延伸元件22且不具有宏观孔或包括开口远端24的离散的延伸元件22的流体不可渗透的纤维网可为其中不要求流体渗透性的任何应用提供柔软性。因此，在一个实施方案中，所述方法生产在其至少一个表面上表现出柔软和丝般触觉印象的压花纤维网16，压花纤维网16的丝般感觉表面表现出离散的延伸元件22的图案，每个离散的延伸元件22均是纤维网表面的突出延伸部并具有限定开口近侧部分30和闭合或开口远端24的侧壁，离散的延伸元件22在开口近侧部分30处或靠近其具有最大的横向截面尺寸。
压花纤维网16也可表现出改善的声音效应。例如，当处理或手工操作时，与前体纤维网34相比，压花纤维网16产生较小的声音。任选地，当触摸或摩擦时，某些压花图案可产生与众不同的所期望的声音。
可最优化离散的延伸元件22的“面密度”，所述面密度为第一表面26的每单位面积上的离散的延伸元件22的数目，并且压花纤维网16通常将包括约4至约10,000，约95至约10,000，约240至约10,000，约350至约10,000，约500至约5,000，或约700至约3,000个离散的延伸元件22/平方厘米。一般来讲，可优化中心至中心间距以便触觉印象适合，而同时最小化离散的延伸元件22之间材料例如流体的捕集。相邻离散的延伸元件22之间的中心至中心间距可为约100微米至约1,000微米，约30微米至约800微米，约150微米至约600微米，或者约180微米至约500微米。
当压花纤维网16用作一次性吸收制品的顶片时，压花纤维网16还可包括允许流体流过压花纤维网16的宏观孔。
用于制造压花纤维网的方法
再次参见图9，用于成形压花纤维网16的方法包括在静压充气室36和成形结构8之间喂送到前体纤维网34，和施加足以使前体纤维网34的各部分适形于成形结构8的离散的突出元件10的来自静压充气室36的气压抵靠前体纤维网34和成形结构8，从而形成具有离散的延伸元件22的压花纤维网16。取决于所产生的压力和成形结构8的形貌，前体纤维网34适形于成形结构8可为部分适形、基本适形或完全适形。尽管不受理论的束缚，据信开口远端24可通过在前体纤维网34适形于成形结构8的离散的突出元件10的同时使前体纤维网34局部破裂而成形。
为了永久地变形前体纤维网34以形成压花纤维网16，外加压力一般足以将所述前体拉伸超过其屈服点。
该方法可为批量方法或连续方法。批量方法可涉及提供单独的前体纤维网34材料片放置在成形结构8和静压充气室36之间。
连续方法可涉及提供前体纤维网34材料卷，将其退绕并送进成形结构8和静压充气室36之间。成形结构8可例如呈辊的形式。当前体纤维网34通过成形结构8辊和静压充气室36之间时，形成了压花纤维网16。
该方法可具有相对短的保压时间。如本文所用，术语“保压时间”是指将压力施加到前体纤维网34的给定部分的时间量，通常前体纤维网34的给定部分放置在成形结构8和静压充气室36之间花费的时间量。所述压力通常被施加到前体纤维网34上不到约5秒，不到约1秒，不到约0.5秒，不到约0.1秒，不到约0.01秒，或则不到约0.005秒的保压时间。例如，保压时间可为约0.5毫秒至约50毫秒。即使用这么相当短的保压时间，也可生产出本文所述的具有所期望的结构特征的压花纤维网。因此，本公开的方法使得能够高速地生产压花纤维网。
前体纤维网34可按至少约0.01米/秒，至少约1米/秒，至少约5米/秒，或至少约10米/秒的速率在成形结构8和静压充气室36之间喂入。其它合适的速率包括例如至少约0.01、0.05、0.1、0.5、1、2、3、4、5、6、7、8、9或10米/秒。
取决于诸如成形结构8的离散的突出元件10的形状和所施加的压力之类的因素，通过本公开的方法生产的压花纤维网16的延伸元件的远端24可为或是闭合的或开口的。
所述方法可在环境温度下执行，意思是没有热量被有意施加到成形结构8和/或前体纤维网34上。然而，应当认识到，由于成形结构8和静压充气室36之间的压力的缘故，可生成热量，尤其是在连续方法中。因此，成形结构8和/或静态气压室的气体可被冷却以便将加工条件维持在所期望的温度例如环境温度。
该方法也可用具有高温的前体纤维网34来进行。例如，前体纤维网34的温度可小于前体纤维网34的熔点。例如，前体纤维网34的温度可为在前体纤维网34的熔点之下至少约10℃。前体纤维网34特别是包括聚乙烯类的前体纤维网34在加工期间可具有约10℃至约200℃，约10℃至约120℃，约20℃至约110℃，约10℃至约80℃，或者约10℃至约40℃的温度。前体纤维网34在加工期间可通过采用用于静压充气室36的热流体压力源加热前体纤维网34和/或通过加热成形结构8而加热。例如，可采用加热的气体作为静压充气室36的压力源。
在一个实施方案中，在成形结构和柔顺基底之间提供前体纤维网之前，不加热所述前体纤维网。在另一个实施方案中，在成形结构和柔顺基底之间提供前体纤维网之前，不加热前体纤维网、成形结构和柔顺基底。
一般来讲，本发明的方法可在约10℃至约200℃，约10℃至约120℃，约10℃至约80℃，或者约10℃至约40℃的温度下来执行。所述温度可通过例如非接触温度计例如红外线温度计或者激光温度计来测量，测量在静压充气室和成形结构8之间的辊隙处的温度。所述温度也可采用温度敏感材料例如得自Paper Thermometer Company的Thermolabel来确定。
用静压充气室36提供平均压力。平均压力足以使被设置在成形结构8和静压充气室36之间的前体纤维网34适形于成形结构8的离散的突出元件10以形成压花纤维网16。一般来讲，在成形结构8和静压充气室36之间所提供的平均压力为约0.1MPa至约25MPa，约1MPa至约20MPa，约0.5MPa至约10MPa，约10MPa至约25MPa，或者约0.5MPa至约5MPa。
所述方法任选地还可包括在在成形结构8和静压充气室36之间提供前体纤维网34之前给前体纤维网34和/或成形结构8施用增滑剂。这对降低前体纤维网34和成形结构8之间的摩擦可为有益的，特别是在连续方法中。适用增滑剂的非限制性实例包括硅氧烷、滑石、润滑油等。
所述方法任选地可与其它方法相组合以进一步处理压花纤维网16。在一个实施方案中，此类附加方法可在同一加工生产线上与所述方法相组合以生产例如吸收制品。在一个实施方案中，将该方法与可在压花纤维网16中赋予宏观孔的方法诸如US 2006/0087053 A1或US 2005/0064136 A1所述的方法相组合。这种方法的组合可生产出可适于用作吸收制品中的顶片的宏孔的压花纤维网16。这种宏孔的压花纤维网16可通过将其与其他吸收制品组件诸如吸收芯、底片等相组合而被后续地转换加工成吸收制品，优选地在相同方法的制造线上进行转换加工。
除了前文所述的方法以外，还设想到用于制造压花纤维网的可供选择的方法。所述方法还可包括施加来自第二压力源的压力。第二压力源可选自由下列组成的组：静态液体压力充气室、静态气体压力充气室、速度气体压力源诸如气刀、速度液体压力源诸如常规的液压成形法中所用的压力源、和柔顺基底。美国临时专利申请号61/159,906公开了用于本公开的方法的一种适用的柔顺基底。由第二压力源作用在前体纤维网34上的压力通常将类似于由前文所述的静压充气室36作用在前体纤维网34上的那些压力。第二压力源可在静压充气室之前或之后顶靠前体纤维网施加压力。例如，所述方法可包括采用多个静压充气室。在一个实施方案中，提供至少两个静压充气室，并且在成形结构8和第一静压充气室之间将压力施加在前体纤维网34的第一部分上。然后可在成形结构8和第二静压充气室之间将压力施加在前体纤维网34的第一部分上。这可进一步使所记录的前体纤维网的一部分适形于成形结构的同一离散的突出元件。这可允许增强通过该方法所形成的离散的延伸元件。
压花纤维网的用途
所述压花纤维网可用于许多不同的方面，包括用作吸收制品的组件材料(诸如顶片、底片或防粘纸包裹物)、包装(诸如流动包裹、收缩包装膜或塑料袋)、垃圾袋，食品包裹物、牙线、擦拭物、电子元件、壁纸、衣服、围裙、窗口覆盖物、餐具垫、书籍封面等。
实施例
下面是用于制造本发明的压花纤维网的方法的非限制性实施例。
实施例1
采用静态气压充气室和具有约1550个离散的突出元件每平方厘米(约10,000个离散的突出元件每平方英寸，100目)的成形结构生产压花纤维网。成形结构由DELRIN Acetal制成并具有约1mm的厚度。离散的突出元件具有约250微米的高度，约105微米的直径(在1/2高度处测量)和约270微米的中心至中心间距。离散的突出元件的侧壁是锥形的，成约8°的角度。突出元件的远端具有约88微米的直径。离散的突出元件相对于相邻的突出元件是偏移的。
所用的前体纤维网34为获自RKW US，Inc.的聚乙烯薄膜，其为约15微米厚并且具有约14.2克/平方米(“gsm”)的基重。
压花方法采用具有成形结构的高速研究压机在约20℃的环境温度下执行。高速研究压机详细描述于美国专利公布号2009/0120308中，并且被设计用来模拟用于压花前体纤维网34的连续生产线工艺。压机包括具有被橡胶(40A硬度氯丁橡胶)围绕着的25mm×25mm开口的进气歧管板，其连接到高压源以传输压力给静态气压室。成形结构接合进气歧管板的橡胶到约1.8mm的压缩距离，在成形结构和橡胶之间密封前体纤维网。从而通过静态气压充气室产生了横跨前体纤维网的压差，其中大气压存在于前体纤维网的面向成形结构侧上以及约2MPa的压力存在于前体纤维网的相对侧上，来自静态气压充充气室。操纵压机来模拟205mm的成形结构辊直径。在成形结构8和静态气压充气室之间以约2.74m/s的模拟速率喂入前体纤维网34。保压时间为约0.19秒。所得的压花纤维网包括具有约100微米的平均高度和开口远端(如图10A所示)或闭合远端(如图10B所示)的离散的延伸元件。
不应将本文所公开的量纲和值理解为对所引用精确值的严格限制。相反，除非另外指明，每个这样的量纲旨在表示所引用的值和围绕该值功能上等同的范围。例如，所公开的量纲“40mm”旨在表示“约40mm”。
除非另行指出，当本文结合一个实施方案公开某个技术特征时，该特征可与其他实施方案或权利要求中所公开的任何其他特征相结合。
在发明详述中所有引用文献的相关部分均引入本发明以供参考。任何文献的引用不可理解为是对其作为本发明的现有技术的认可。当本文件中术语的任何含义或定义与以引用方式并入的文件中同一术语的任何含义或定义矛盾时，应当服从在本文件中赋予该术语的含义或定义。
尽管已用具体实施方案来说明和描述了本发明，但是对那些本领域的技术人员显而易见的是，在不背离本发明的实质和范围的情况下可作出许多其它的改变和变型。因此，这意味着在所附权利要求中包括了属于本发明范围内的所有这些变化和修改。

Claims (16)

1.一种用于制造压花纤维网的方法，所述方法包括：
在静态气压充气室和包括多个离散的突出元件的成形结构之间喂入前体纤维网，所述离散的突出元件具有至少等于所述前体纤维网厚度的高度；以及
从所述静态气压充气室抵靠与所述成形结构相对的前体纤维网施加压力，产生足以使前体纤维网适形于所述成形结构的离散的突出元件的横跨所述前体纤维网的压差，从而形成包括多个离散的延伸元件的压花纤维网，所述离散的延伸元件具有开口近端。
2.如权利要求1所述的方法，所述方法包括在所述静态气压充气室和所述成形结构之间以至少1米/秒的速率喂入所述前体纤维网。
3.如权利要求1所述的方法，所述方法包括施加压力并持续1毫秒至5秒的保压时间。
4.如权利要求1-3中的任一项所述的方法，其中所述前体纤维网在所述方法过程中的温度小于所述前体纤维网的熔点。
5.如权利要求4所述的方法，其中所述前体纤维网的温度低于所述前体纤维网的熔点至少10℃。
6.如权利要求1-3中的任一项所述的方法，其中所述前体纤维网的温度在加工期间为20℃至110℃。
7.如权利要求1-3中的任一项所述的方法，其中所述静态气压充气室的气体包括至少一种选自由氮气、二氧化碳、以及它们的混合物组成的组的气体。
8.如权利要求1-3中的任一项所述的方法，其中所述静态气压充气室的气体包括空气。
9.如权利要求1-3中的任一项所述的方法，其中所述压花纤维网的延伸元件具有开口远端。
10.如权利要求1-3中的任一项所述的方法，其中所述压花纤维网的延伸元件具有闭合的远端。
11.如权利要求1-3中的任一项所述的方法，其中所述压花纤维网的延伸元件具有至少0.2的纵横比。
12.如权利要求1-3中的任一项所述的方法，其中所施加的压力为0.1MPa至25MPa。
13.如权利要求12所述的方法，其中所施加的压力为0.5MPa至5MPa。
14.如权利要求1-3中的任一项所述的方法，其中所述延伸元件相对于所述前体纤维网的厚度被减薄。
15.如权利要求1-3中的任一项所述的方法，其中所施加的压力足以拉伸所述前体纤维网超出所述前体纤维网的屈服点。
16.如权利要求1-3中的任一项所述的方法，其中所述前体纤维网选自由聚丙烯、聚乙烯以及它们的混合物组成的组。
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