CN102348439A - 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
CN102348439A
CN102348439A CN2010800113688A CN201080011368A CN102348439A CN 102348439 A CN102348439 A CN 102348439A CN 2010800113688 A CN2010800113688 A CN 2010800113688A CN 201080011368 A CN201080011368 A CN 201080011368A CN 102348439 A CN102348439 A CN 102348439A
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CN
China
Prior art keywords
precursor web
shaped structure
embossing
microns
discrete
Prior art date
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Granted
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CN2010800113688A
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English (en)
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CN102348439B (zh
Inventor
K.G.马斯
R.G.科伊
K.J.斯通
S.B.格罗斯
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Procter and Gamble Ltd
Procter and Gamble Co
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Procter and Gamble Ltd
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Publication of CN102348439A publication Critical patent/CN102348439A/zh
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
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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。在成形结构和柔顺基底之间提供前体纤维网。该成形结构具有多个离散的孔或凹陷。在柔顺基底和成形结构之间提供压力以迫使前体纤维网进入到成形结构的孔或凹陷中从而形成压花纤维网。所得压花纤维网具有多个离散的延伸元件。

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。然后空气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，所得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。因此，由于加热步骤和真空成形法所产生的压力有限，该方法为一种低效的方法。
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。
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，本发明提供了一种用于形成压花纤维网的方法，所述方法包括在柔顺基底和成形结构之间喂入前体纤维网，所述成形结构包括多个离散的孔、离散的凹陷、或它们的组合。所述孔或凹陷具有至少大体上等于前体纤维网的厚度的深度。该方法还包括在柔顺基底和成形结构之间施加压力，所述压力足以迫使柔顺基底接触前体纤维网并且足以迫使前体纤维网的部分进入到由孔或凹陷限定的空隙体积中，从而形成压花纤维网。所述压花纤维网包括具有开口近端的多个离散的延伸元件。
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，本发明的附加特征可变得显而易见。
附图简述
图1为根据本公开的一个实施方案的成形结构的顶视图；
图2为根据本公开的一个实施方案的成形结构的透视图，示出了孔和凹陷之间的区别；
图3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4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5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显微照片，所述压花纤维网具有包括闭合远端的离散的延伸元件；
图7为图6的压花纤维网的放大显微照片；
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显微照片，所述压花纤维网具有包括开口远端的离散的延伸元件；
图9为图8的压花纤维网的放大显微照片；
图10为根据本公开的一个实施方案的用于制造压花纤维网的连续方法的示意图；
图11为曲线图，示出了随压缩距离和进料速率而变的离散的延伸元件的平均高度；并且
图12为曲线图，示出了随压缩距离而变的离散的延伸元件的平均高度。
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。
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。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。
参见图1，该方法一般包括在柔顺基底36和成形结构10之间喂入前体纤维网34，所述成形结构包括多个离散的孔12、离散的凹陷14、或它们的组合。孔12或凹陷14具有至少大体上等于前体纤维网34的厚度，并且优选地至少三倍的前体纤维网34的厚度的深度。该方法还包括在柔顺基底36和成形结构10之间施加压力，所述压力足以迫使柔顺基底36接触前体纤维网34并且足以迫使前体纤维网34的部分进入到由孔12或凹陷14限定的空隙体积中，从而形成压花纤维网16。压花纤维网16包括具有开口近端30的多个离散的延伸元件22。该方法的这些方面将在下文中更详细地描述。
成形结构
参见图1和2，适用于本公开的方法的成形结构10包括多个离散的孔12、离散的凹陷14、或它们的组合。成形结构10还可包括完全围绕离散的孔12或凹陷14的陆地13。相对于常规压花方法中的成形结构上所用的典型图案来讲，成形结构10的离散的孔12或凹陷14在尺度上较小。本公开的方法可生产出包括具有薄化远端24的相对高纵横比的延伸元件的压花纤维网，甚至在不加热前体纤维网34的情况下且甚至以高速运行时也是如此。
成形结构10有时候被称为成形筛网。图2示出了孔12和凹陷14之间的区别。如本文所用，“孔”是指成形结构10中的开口，所述开口不包括限制所述开口的深度的底部表面。相比之下，如本文所用，“凹陷”是指成形结构10中的具有底部表面的开口，所述底部表面将所述开口的深度限制成小于成形结构10的厚度。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，所述开口具有小于凹陷14的直径的宽度，所述开口通过允许空气穿过凹陷14而使凹陷14通气。在一个实施方案中，成形结构具有某种部件以允许任何被截留在纤维网下面的空气逸出。例如，可提供真空辅助以除去纤维网下面的空气以便不增加所需的柔顺压力。底部表面可为平坦的、圆化的或尖锐的。成形结构10可为实心辊，或具有约25微米至约5000微米，或约100微米至约3000微米的厚度。凹陷14可具有在约10微米至约500微米，或约25微米至约5000微米范围内的深度。如本文所用，孔的深度对应于成形结构的厚度，因为孔12不具有限制其深度的底部表面。在一个实施方案中，孔12和凹陷14可具有大体上等于前体纤维网34的厚度，至少两倍的前体纤维网34的厚度，或至少三倍的前体纤维网34的厚度的深度。
成形结构10的前体纤维网34接触表面上的孔12或凹陷14的周边可具有直边或可具有曲率半径，所述曲率半径从成形结构10的前体纤维网34接触表面测量到孔12或凹陷14中。曲率半径可为约0微米至约2000微米，优选地约0微米至约25微米，并且更优选地约2微米至约25微米。在一个实施方案中，使用通常称作斜面的成角度的锥形。在一个实施方案中，使用直边和半径的组合。
孔12或凹陷14具有直径，就大致圆柱形结构而言，所述直径为内径。就孔12或凹陷14的非均匀横截面、和/或非圆柱形结构而言，将直径测量为孔12或凹陷14在成形结构的顶部表面处的平均横截面尺寸。每个孔12或凹陷14可具有约10微米至约5mm的直径。其他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25000微米，约500微米至约5000微米，或约800微米至约2500微米的直径。在某些实施方案中，孔12或凹陷14可具有更大的直径以便形成宏观尺度的离散的延伸元件。例如，孔12或凹陷14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，孔12或凹陷14的直径为恒定的或随着深度的增加而减小。在另一个实施方案中，孔12或凹陷14的直径随着深度的增加而增加。例如，离散的孔12或凹陷14可具有第一深度处的第一直径和深于第一深度的第二深度处的第二直径。例如，第一直径可大于第二直径。例如，第二直径可大于第一直径。
离散的孔12或凹陷14的侧壁可为完全竖直的或可为锥形的。在一个实施方案中，离散的孔12或凹陷14具有锥形的侧壁。这可允许纤维网在压花之后更容易地与成形结构10分离。在一个实施方案中，侧壁通常将具有约0°至约-50°至约50°，约-30°至约30°，约0°至约50°，约2°至约30°，或约5°至约25°的锥度。
成形结构10的离散的孔12或凹陷14可具有多种不同的横截面形状，诸如大致柱状或非柱状形状，包括圆形、椭圆形、沙漏形、星形、多边形等、以及它们的组合。多边形横截面形状包括但不限于矩形、三角形、六边形、或梯形。在一个实施方案中，离散的凹陷14可具有大体上等于成形结构10的长度的长度以便围绕成形结构10的大体上整个长度形成凹槽。例如，当成形结构10呈辊形式时，凹槽可围绕所述辊的整个圆周而形成。凹槽可为大体上直的(例如，一致地平行于辊的边缘)或可为波状的。
一般来讲，成形结构10就其给定部分而言将包括至少约95个离散的孔12或凹陷14/平方厘米，至少约240个离散的孔12或凹陷14/平方厘米，约350至约10,000个离散的孔12或凹陷14/平方厘米，约500至约5,000个离散的孔12或凹陷14/平方厘米，或约700至约3,000个离散的孔12或凹陷14/平方厘米。在某些实施方案中，孔12或凹陷14可具有大于约1cm的直径。此类更大尺寸的孔12或凹陷14可适用于形成具有更大尺寸的离散的延伸元件的压花纤维网，例如用作包装材料。在这些实施方案中，成形结构10就其给定部分而言可包括约1至约5个离散的孔12或凹陷14/10平方厘米。
孔12或凹陷14可具有约30微米至约1000微米，约30微米至约640微米，约150微米至约500微米，或约180微米至约430微米的两个相邻孔12或凹陷14之间的平均边至边间距。在某些实施方案中，成形结构10的一部分(或区域)可包括如前段所述面密度的离散的孔12或凹陷14，而成形结构10的其他部分(或区域)可不包括离散的孔12或凹陷14。不具有离散的孔12或凹陷14的成形结构10的区域可定位在不同的水平面中。在其他实施方案中，成形结构10的离散的孔12或凹陷14可定位在成形结构10的不同的水平面中。定位在成形结构10的不同的水平面中的不具有离散的孔12或凹陷14的区域和/或具有离散的孔12或凹陷14的区域可呈具体图案或设计的形式，诸如花、鸟、条带、波纹、卡通人物、徽标等形式，以便压花纤维网16将具有如下的区域，所述区域相对于纤维网的剩余部分在视觉上突显出来、和/或当触摸时具有不同的手感和/或不同的声音。例如，压花纤维网16可包括相对于压花区域在视觉上突显出来、和/或具有不同于压花区域的手感的非压花区域。美国专利5,158,819(其公开内容以引用方式并入本文)提供了可用于这些实施方案的成形结构的合适的实例。
在一个实施方案中，孔12或凹陷14的平均深度对前体纤维网34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，至少约5∶1，或至少约10∶1。该比率可为重要的，以确保前体纤维网34受到足够的拉伸以便其被永久地变形以产生压花纤维网16，尤其是以所期望的工艺条件和速度来拉伸。
成形结构10可由任何材料制成，所述材料可被成形成包括具有必要尺寸的孔12或凹陷14以制造出压花纤维网16，并且在成形结构10所经受的工艺温度和压力范围内是尺寸上稳定的。
在一个实施方案中，具有所需的相对小尺度的孔12或凹陷14的成形结构10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。
在一种制造合适的成形结构10的方法中，将易于激光修改的基体材料进行激光“蚀刻”以选择性地除去材料从而形成孔12或凹陷14。所谓“易于激光修改的”，是指材料可通过激光以受控方式来选择性地除去，应当认识到，在所述激光加工中所用的光的波长以及功率水平可能需要适配于所述材料(或反之亦然)以便产生最佳结果。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修改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(Wilmington DE，USA)的
Figure BDA0000090648950000071
热固性塑料诸如交联聚酯、或环氧化物、或甚至金属诸如铝、铜、黄铜、镍、不锈钢、或它们的合金。任选地，可将热塑性材料和热固性材料填充上颗粒或纤维填料以增加与某些波长的激光的相容性和/或改善模量或韧性以制造出更耐用的孔12或凹陷14。例如，通过用足够量的中空碳纳米管纤维均匀地填充某些聚合物诸如PEEK，可以更高的分辩率并以更高的速度来激光加工所述聚合物。
在一个实施方案中，可以连续方法来激光加工成形结构10。例如，可将聚合材料诸如
Figure BDA0000090648950000072
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孔12或凹陷14。
成形结构10可呈如下形式：平坦板、辊、带、环形带、套管等。在一个优选的实施方案中，成形结构10呈辊形式。在另一个优选的实施方案中，成形结构10呈环形带形式。环形带可根据美国专利7,655,176、6,010,598、5,334,289和4,529,480的教导来形成。
成形结构10还可任选地包括离散的突起元件。离散的突起元件可为尺寸得当的和成型的，并且可如美国临时专利申请号61/159,906所述的那样来成型。如果成形结构10还包括突起元件，则可迫使前体纤维网34贴附到成形结构10的突起元件上，使得离散的延伸元件22可在前体纤维网34中形成，所述延伸元件从前体纤维网34的表面伸出，所述表面与成形结构10的孔12或凹陷14在其处形成离散的延伸元件22的表面相对。因此，可产生两面的压花纤维网16，在压花纤维网16的每个侧面上具有不同图案或尺寸的延伸元件。取决于在成形结构10和柔顺基底36之间所产生的压力、以及成形结构10的孔12或凹陷14和任选的柱或脊的几何形状，压花纤维网16的离散的延伸元件22可具有闭合远端或开口远端24。
柔顺基底
柔顺基底36用来提供顶压成形结构10的力。在最低限度上，柔顺基底36的外表面(即，柔顺基底36的朝成形结构10取向的表面)包括柔顺材料40。例如，柔顺基底36可包括由柔顺材料40覆盖的刚性材料38。刚性材料38可为金属(诸如钢)、塑料、或任何其他显著地硬于柔顺材料40的材料。覆盖刚性材料38的柔顺材料40的厚度通常将不大于约26mm，并且优选地为约1mm至约26mm，更优选地约1mm至约7mm。作为另外一种选择，整个柔顺基底36均可由柔顺材料40制成。
柔顺基底36或柔顺材料40可包括弹性体、毡、充液囊状物、充气囊状物、以及它们的组合。在一个实施方案中，柔顺基底36为多孔弹性体。柔顺基底36或柔顺基底36中所用的柔顺材料40优选地具有弹力特性(诸如压缩恢复)使得柔顺材料40足够快速地回弹以有利于该方法，尤其是连续方法的进行。
柔顺基底36或柔顺基底36中所用的柔顺材料40优选地也具有足够的耐久性以压花大量的前体纤维网34材料。因此，柔顺基底36优选地具有合适的耐磨度，其中在该方法期间柔顺基底36将趋于被成形结构10磨蚀。
柔顺基底36可呈如下形式：平坦板、辊、带、环形带、套管等。在一个实施方案中，柔顺基底36为用柔顺材料40诸如弹性体覆盖的金属辊。在另一个实施方案中，柔顺基底36和成形结构10两者均呈辊的形式。在另一个实施方案中，柔顺基底36为辊，其具有大于成形结构10辊的直径的直径。在另一个实施方案中，柔顺基底36为辊，其具有小于成形结构10辊的直径的直径。在另一个实施方案中，柔顺基底36辊具有与成形结构10辊的直径相同的直径。
柔顺基底36或柔顺基底36中所用的柔顺材料40通常将具有约30至约80硬度计，优选地约30至约60硬度计，并且更优选地约40至约70硬度计的按肖氏硬度A标度计的硬度。以肖氏硬度A标度计的硬度通常通过使用ASTM D2240硬度计诸如得自PTC Instruments(Los Angeles，California)的型号为306的A型经典式硬度计来确定。应当认识到，柔顺基底36可表现出变化的硬度，例如靠近外表面的硬度较低，并且朝柔顺基底36的内表面的硬度较高(即在柔顺基底36的z方向上变化的硬度)或在柔顺基底36的外表面上变化的硬度(即在柔顺基底36的x-y平面中变化的硬度)。
柔顺基底36中所用的柔顺材料40通常将具有约1至约20MPa，优选地约2至约18MPa，并且更优选地约3至约10MPa的拉伸模量。柔顺材料40的拉伸模量可在0.1sec-1的应变速率下确定。
合适的柔顺材料的非限制性实例包括天然橡胶、尿烷橡胶、聚氨酯橡胶、氯磺化聚乙烯橡胶(以商品名
Figure BDA0000090648950000091
得自DuPont)、氯丁二烯橡胶、降冰片烯橡胶、腈橡胶、氢化腈橡胶、苯乙烯橡胶、丁苯橡胶、丁二烯橡胶、硅橡胶、乙烯-丙烯-二烯(“EPDM”)橡胶、异丁烯-异戊二烯橡胶、毡(诸如压制的羊毛毡)等。尤其适用的柔顺材料为异戊二烯、EPDM、氯丁橡胶、和
Figure BDA0000090648950000092
它们具有约30至约50硬度计，约40至约70硬度计，或约60至约80硬度计的肖氏硬度A。
柔顺材料40也可为诸如吸收芯之类的材料，所述材料可与前体纤维网34一起在刚性材料38和成形结构10之间喂入。这种材料可用来产生顶压前体纤维网34和成形结构10的压力以便压花前体纤维网34。然后可将这种材料与压花纤维网16一起结合到成品消费品诸如妇女卫生制品中。
柔顺基底36可任选地包括凹进区域，所述凹进区域的深度足以防止前体纤维网34在特定区域中压花或在特定区域中仅最低程度地压花前体纤维网34。柔顺基底36的任选的凹进区域可呈具体图案或设计的形式，诸如花、鸟、条带、波纹、卡通人物、徽标等形式，以便压花纤维网16将具有未压花区域，所述未压花区域相对于压花纤维网16的压花区域在视觉上突显出来、和/或当触摸时具有不同的手感、和/或具有不同的声音。
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。合适的前体纤维网包括可被在成形结构10和柔顺基底36之间产生的压力变形的材料，使得前体纤维网34能够适形于成形结构10的外形以生产出压花纤维网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。合适的前体纤维网的非限制性实例包括薄膜，诸如聚合物薄膜或热塑性薄膜、薄片诸如金属薄片(例如铝、黄铜、铜等)、包括供应充足的聚合物的纤维网、泡沫、包括合成纤维(例如
Figure BDA0000090648950000101
的纤维质非织造纤维网、胶原薄膜、脱乙酰壳多糖薄膜、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 BDA0000090648950000102
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。其他合适的厚度包括约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215℃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。可期望前体纤维网34的应变硬化特性有利于前体纤维网34适形于成形结构10的离散的突起元件。这可优选地用于生产压花纤维网，其中期望具有压花纤维网16的延伸元件的闭合远端24。
前体纤维网34可为任何材料诸如聚合物薄膜，所述材料具有足够的材料特性从而通过本公开的压花方法成形为本文所述的压花纤维网16。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。即，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可被无破裂地应变至某种程度以生产出所期望的具有闭合远端24的离散的延伸元件22，或在包括具有开口远端24的离散的延伸元件22的压花纤维网的情形中，产生破裂以形成开口远端24。如下所述，工艺条件如温度可因给定的聚合物而有变化以允许其有破裂或无破裂地拉伸，以形成具有所期望的离散的延伸元件22的压花纤维网16。因此，一般来讲，已发现优选的要用作用于生产压花纤维网16的前体纤维网34的起始材料表现出低屈服和高伸长特性。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也必须为足够可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限度时，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微米的厚度的该材料的薄膜可具有至少12MPa的拉伸屈服；至少53MPa的极限拉伸；至少635％的极限伸长率；和至少210MPa的拉伸模量(2％正割)(上述每一测量值均是根据ASTM D 882确定的)。其他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包括三层的共挤出的层压体，所述层压体具有约25微米(0.001in.)的总体厚度，其中芯层具有约18微米(0.0007in.)的厚度；并且每个表皮层均具有约3.5微米(0.00015in.)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。如果需要包含共混物的层，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还可任选地包含表面活性剂。如果要利用的话，优选的表面活性剂包括源自非离子类的那些，诸如：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。
如果要利用的话，初始时共混到前体纤维网34中的表面活性剂的含量可多达按总前体纤维网34的重量计10％。在所述优选的分子量范围(300-1,000克/摩尔)内的表面活性剂可按较低的含量，一般为或低于总前体纤维网34的约5％重量的含量加入。
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含二氧化钛。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诸如低密度聚乙烯的重量计至多约10％的量加入。
可任选地在前体纤维网34的一个或多个层中加入其他添加剂诸如颗粒材料，例如粒状皮肤护理剂或保护剂、或气味吸收活性物质例如沸石。在一些实施方案中，当用于皮肤接触应用时，包含颗粒物质的压花纤维网可允许活性物质以非常直接和高效的方式接触皮肤。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的话，则颗粒材料的平均粒度通常将为约0.2至约200微米或约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、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也可任选地包含填料、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定位在所提供的成形结构10和柔顺基底36之间以使前体纤维网34适形于成形结构10的离散的孔12或凹陷14。参见图3，从而生产出具有离散的延伸元件22的压花纤维网16。如图4所示，离散的延伸元件22具有开口近端30和开口(如图5，8和9所示)远端和/或闭合(如图3，4，6和7所示)远端24。
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，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3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。对于诸如一次性吸收制品或包装中的顶片、底片或防粘纸包裹物之类的应用，可期望离散的延伸元件22仅从压花纤维网16的一个表面突起。因此，当压花纤维网16用作一次性吸收制品中的顶片时，压花纤维网16可取向成使得离散的延伸元件22为被皮肤接触的以便产生优异的柔软印象。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12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4，离散的延伸元件22可被描述为从压花纤维网16的第一表面26突起。因此，离散的延伸元件22可被描述为与前体纤维网34成一整体，并且通过永久地局部塑性变形前体纤维网34来形成。离散的延伸元件22可被描述为具有侧壁28，所述侧壁限定开口近侧部分和闭合远端或开口远端24。离散的延伸元件22各自具有高度h，所述高度从相邻延伸元件之间的最小振幅Amin测量至闭合远端或开口远端24处的最大振幅Amax。离散的延伸元件22具有直径d，就大致圆柱形结构10而言，所述直径为横向截面的外径。所谓“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，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，或至多约0.1厘米的更大的直径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33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。同样，对于变化的横截面尺寸，可针对多个离散的延伸元件33来确定平均直径davg。此类平均直径davg通常将落在上述直径的范围内。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可为近侧部分处的最大值，并且横向截面尺寸稳固地减小至远端。据信可期望该结构10帮助确保压花纤维网16容易地从成形结构10上除去。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加而增加。例如，离散的延伸元件22可具有蘑菇形状。
前体纤维网34的薄化可由于形成高纵横比的离散的延伸元件22所需的相对深拉而发生。例如，可在或靠近闭合远端或开口远端24处观察到薄化。所谓“观察到”是指当在放大的横截面中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，当某个人触摸到压花纤维网16的表现出离散的延伸元件22的侧面时，其指尖首先接触离散的延伸元件22的闭合远端或开口远端24。由于离散的延伸元件22的高纵横比、和前体纤维网34在或靠近远端24处的壁的薄化，离散的延伸元件22会对由人的手指施加在压花纤维网16上的压缩或剪切提供极小的阻力。这种阻力的缺乏表现为柔软感，非常类似于丝绒织物的触感。
前体纤维网34在或靠近闭合远端或开口远端24处的薄化可相对于前体纤维网34的厚度或相对于完全围绕压花纤维网16的离散的延伸元件22的着陆区域的厚度来测量。前体纤维网34通常将相对于前体纤维网34的厚度表现出至少约25％，至少约50％，或至少约75％的薄化。前体纤维网34通常将相对于围绕压花纤维网16的离散的延伸元件22的着陆区域的厚度表现出至少约25％，至少约50％，或至少约75％的薄化。
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12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，该方法生产出压花纤维网16，所述压花纤维网在其至少一个表面上表现出柔软且丝般触觉印象，压花纤维网16的丝感表面表现出离散的延伸元件22的图案，每一离散的延伸元件22均为纤维网表面的突起延伸部并且具有限定开口近侧部分和闭合远端或开口远端24的侧壁，离散的延伸元件22在或靠近开口近侧部分具有最大横向截面尺寸。
压花纤维网16也可表现出改善的声音效应。例如，当被抓持或手动操纵时，压花纤维网16与前体纤维网34相比产生较小的声音。任选地，当被触摸或摩擦时，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，可最优化中心至中心间距以便产生足够的触觉印象，而同时可最小化材料诸如流体在离散的延伸元件22之间的截留。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
参见图10，用于形成压花纤维网16的方法包括在柔顺基底36和成形结构10之间喂入前体纤维网34、以及在柔顺基底36和成形结构10之间施加压力，所述压力足以迫使柔顺基底36接触前体纤维网34并且足以迫使前体纤维网34的部分进入到由成形结构10的孔12或凹陷14限定的空隙体积中，从而形成具有离散的延伸元件22的压花纤维网16。前体纤维网34对成形结构10的适形可为局部适形、基本适形或完全适形，这取决于所产生的压力和成形结构10的外形。不受理论的约束，据信开口远端24可通过在迫使前体纤维网34进入到成形结构10的孔12或凹陷14中的同时局部地破裂前体纤维网34来形成。
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放置在成形结构10和柔顺基底36之间的单个前体纤维网34材料片，所述成形结构和柔顺基底通常各自呈平坦板形式。在一个实施方案中，成形结构10和柔顺基底36各自呈平坦板形式，它们被放置在液压机或平压裁断机中。液压机的一个实例以商品名型号C得自Carver，Inc.。将前体纤维网34放置在成形结构10板和柔顺基底36板之间，并且通过液压机施加压力以使前体纤维网34适形于成形结构10从而生产出压花纤维网16。
连续方法可涉及提供前体纤维网34材料辊，将所述辊退绕并在成形结构10和柔顺基底36之间喂入，所述成形结构和柔顺基底各自可例如呈辊的形式。例如，柔顺基底36辊可包括刚性辊，诸如用柔顺材料40覆盖的钢辊。柔顺材料40可具有约3mm的厚度。随着前体纤维网34从成形结构10辊和柔顺基底36辊之间穿过，形成压花纤维网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”是指压力被施加到前体纤维网34的给定部分上时的时间量，通常所述时间量用于使前体纤维网34的给定部分定位在成形结构10和柔顺基底36之间。所述压力通常被施加到前体纤维网34上并持续小于约5秒，小于约1秒，小于约0.1秒，小于约0.01秒，小于约0.005秒，或小于约0.002秒的保压时间。例如，保压时间可为约0.5毫秒至约50毫秒。
即使用此类相对短的保压时间，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10和柔顺基底36之间喂入。其他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10上的孔12或凹陷14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出的压花纤维网16的延伸元件的远端24可为闭合的或开口的。
该方法可在环境温度下进行，这意味着无需有意地加热成形结构10、柔顺基底36、和/或前体纤维网34。然而，应当认识到，会由于成形结构10和柔顺基底36之间的压力而产生热，尤其是在连续方法中更是如此。因此，可冷却成形结构10和/或柔顺基底36以便将工艺条件保持在所期望的温度诸如环境温度并且改善柔顺基底的耐久性。
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的熔点34。例如，前体纤维网34的温度可低于前体纤维网的熔点34至少约10℃。前体纤维网34尤其是包括聚乙烯的前体纤维网34在该方法期间可具有约10℃至约120℃，约20℃至约110℃，约10℃至约80℃，或约10℃至约40℃的温度。前体纤维网34在该方法期间可通过加热前体纤维网34、柔顺基底36、和/或成形结构10来加热。
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℃，或约10℃至约40℃的温度下进行。所述温度可通过例如非接触式温度计诸如红外温度计或激光温度计来测量，测量柔顺基底36和成形结构10之间的辊隙处的温度。所述温度也可使用温度敏感材料诸如得自Paper Thermometer Company的温度标贴来确定。
在柔顺基底36和成形结构10之间提供平均压力。所述平均压力足以迫使定位在成形结构10和柔顺基底36之间的前体纤维网34进入到成形结构10的离散的孔12或凹陷14中以形成压花纤维网16。一般来讲，在成形结构10和柔顺基底36之间提供的平均压力为约1MPa至约100MPa，约5MPa至约70MPa，约10MPa至约60MPa，或约20MPa至约40MPa。例如，外加压力可为至多约30MPa。
在成形结构10和柔顺基底36之间提供的平均压力可被确定为每单位面积上的力。向成形结构10和/或柔顺基底36上施加力以便柔顺基底36被顶靠成形结构10按压至如下文所述的所期望的压缩距离。所述单位面积为成形结构10和柔顺基底36之间的接触面的面积。从这些值可计算出成形结构10和柔顺基底36之间的平均压力。
如果成形结构10和柔顺基底36两者均为平坦板，则成形结构10和柔顺基底36之间的接触面的面积通常容易地基于平坦板的尺寸来确定。
如果成形结构10和柔顺基底36两者均为辊，则成形结构10和柔顺基底36之间的接触面的面积可通过将所述辊静态加载上提供在所述辊之间的一片压敏薄膜来确定。一种合适的压敏薄膜为得自FUJIFILM NDT Systems的Fuji Prescale Film，在向所述薄膜上施加压力时其经历某些颜色变化。释放辊上的静态载荷并且从辊上除去压敏薄膜。压敏薄膜将具有代表成形结构10和柔顺基底36之间的接触面的颜色变化区域。使用该接触面面积和施加到成形结构10辊和/或柔顺结构10辊上的力，可计算出在成形结构10辊和柔顺结构10辊之间提供的平均压力。
通过向成形结构10和/或柔顺基底36上施加力来将成形结构10和柔顺基底36按压至所期望的压缩距离。“压缩距离”通过测量成形结构10被顶靠按压柔顺基底36的距离来确定。该距离可通过使成形结构10和柔顺基底36初始地接触然后迫使成形结构10和柔顺基底36结合在一起来测量。初始接触之后的成形结构10和柔顺基底36相对于彼此移动的距离被称为“压缩距离”。如果成形结构10和柔顺基底36两者均为辊，则压缩距离可被测量为由于在初始接触之后所施加的力而引起的成形结构10的旋转轴线和柔顺基底36的旋转轴线之间的距离的变化。
成形结构10至柔顺基底36的压缩距离通常将为约1mm至10mm，约0.1mm至约5mm，约0.2mm至约4mm，或约0.3mm至约3mm。
成形结构10和柔顺基底36可用于低应变速率方法诸如美国专利申请2008/0224351 A1所述的低应变速率方法以生产出压花纤维网16。本公开包括这种方法。
该方法还可任选地包括在成形结构10和柔顺基底36之间提供前体纤维网34之前向前体纤维网34、成形结构10、和/或柔顺基底36上施加增滑剂。这可为有益的，尤其是在连续方法中更是如此，以减小前体纤维网34和成形结构10之间的摩擦。合适的增滑剂的非限制性实例包括硅氧烷、滑石、润滑油等。
该方法可任选地包括向压花纤维网上施加正压力以再反向可能在从成形结构10和柔顺基底36之间除去压花纤维网期间已反向的离散的延伸元件22。可通过施加正压力诸如用气刀施加正压力来再反向已反向过的离散的延伸元件22以从压花纤维网第一表面26伸出，所述正压力足以再反向已反向过的离散的延伸元件22。
该方法可任选地与其他方法相组合以进一步操纵压花纤维网16。在一个实施方案中，此类附加方法可在相同方法的制造线上与该方法相组合以生产出例如吸收制品。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开宏观孔的压花纤维网16。这种开宏观孔的压花纤维网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。该方法还可包括从第二压力源例如除了第一柔顺基底以外的压力源来施加压力。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。2010年3月11日提交的题目为“PROCESS FOR MAKINGAN EMBOSSED WEB”(P&G案号11636)的共同未决的美国专利申请____/____，____公开了一种可用于本公开的方法的合适的静态压力充气室。其他合适的可用于本公开的方法的静态压力充气室包括描述于2010年3月11日提交的题目为“APPARATUS FOR EMBOSSING AWEB”(P&G案号11639P)的美国临时专利申请序列号____/____，____、和美国专利5,972,280中的那些。由第二压力源施加在前体纤维网34上的压力通常将类似于由前文所述的柔顺基底施加在前体纤维网34上的那些压力。第二压力源可在柔顺基底之前或之后顶靠前体纤维网施加压力。在一个实施方案中，提供至少两个柔顺基底，并且在成形结构10和第一柔顺基底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10和第二柔顺基底之间将压力施加在前体纤维网34的第一部分上。这可进一步迫使前体纤维网的所述部分配准于成形结构的相同的孔或凹陷。这可允许增强通过该方法所形成的离散的延伸元件22。
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
实施例1：
使用5.88mm厚40A天然橡胶的柔顺基底36和具有约486个孔/平方厘米的成形结构10生产出了压花纤维网。柔顺基底36具有约40的肖氏硬度A。柔顺基底呈25.4mm×25.4mm的正方形片的形式。
所述成形结构具有约2.25mm的厚度。这些孔具有在顶部表面处的包括约250微米直径的圆形横截面、和从孔的顶部表面进入到孔深处的2°的锥形。这些孔具有约200微米的边至边间距。
所用的前体纤维网34为获自RKW US，Inc.的聚乙烯/聚丙烯共混薄膜，其为约15微米厚并且具有14.2克/平方米(“gsm”)的基重。
压花方法使用高速研究机在室温下进行。高速研究机详述于美国专利公开2009/0120308中，并且被设计成模拟用于压花前体纤维网34的连续生产线方法。操作所述研究机以模拟柔顺基底和205mm的成形结构辊直径。以约2.74m/sec和约7m/sec的模拟速率在成形结构10和柔顺基底36之间喂入前体纤维网34。
表1示出了柔顺基底和成形结构之间的压缩距离、外加压力和柔顺基底中的压缩应变以及压花纤维网的离散的延伸元件22的平均高度。图11示出了进料速率和压缩距离对离散的延伸元件高度的影响。
表1：
Figure BDA0000090648950000221
所述数据表明，延伸元件高度一般随着压缩距离的增加而增加；并且随着进料速率的增加，离散的延伸元件的平均高度减小。
实施例2：
使用3.28mm厚40A天然橡胶的柔顺基底36和具有约1550个孔/平方厘米的成形结构10生产出了压花纤维网。柔顺基底36具有约40的肖氏硬度A。柔顺基底呈25.4mm×25.4mm的正方形片的形式。
所述成形结构具有约1.02mm的厚度。这些孔具有在顶部表面处的包括约147微米直径的圆形横截面和从孔的顶部表面进入到孔深处的2°的锥形。这些孔具有约107微米的边至边间距。
所用的前体纤维网34为获自RKW US，Inc.的聚乙烯/聚丙烯共混薄膜，其为约15微米厚并且具有14.2克/平方米(“gsm”)的基重。
压花方法使用前述实例中所述的高速研究机来进行。操作所述研究机以模拟柔顺基底和205mm的成形结构辊直径。以6m/sec的模拟速率在成形结构10和柔顺基底36之间喂入前体纤维网34。
表2示出了柔顺基底和成形结构之间的压缩距离、外加压力、和应变速率以及压花纤维网的离散的延伸元件22的平均高度。
Figure BDA0000090648950000231
所述数据表明，随着压缩距离的增加，所需的压力和离散的延伸元件的平均高度也增加(图12)。
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。
在发明详述中引用的所有文件都在相关部分中以引用方式并入本文。对任何文献的引用均不应解释为承认其是关于本发明的现有技术。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。
尽管已说明和描述了特定实施方案，但对于本领域的技术人员来讲显而易见的是，在不脱离本发明的实质和范围的情况下，可作出各种其他的改变和变型。因此，所附权利要求旨在涵盖处于本发明范围内的所有这些改变和变型。

Claims (16)

1.一种用于制造压花纤维网的方法，所述方法包括：
在柔顺基底和成形结构之间喂入前体纤维网，所述成形结构包括多个离散的孔、离散的凹陷、或它们的组合，所述孔或凹陷具有至少大体上等于所述前体纤维网的厚度的深度；以及
在所述柔顺基底和所述成形结构之间施加压力，所述压力足以迫使所述柔顺基底与所述前体纤维网接触并且足以迫使所述前体纤维网的一些部分进入到由所述孔或凹陷限定的空隙体积中，从而形成包括多个离散的延伸元件的压花纤维网，所述延伸元件具有开口近端。
2.如权利要求1所述的方法，所述方法还包括以至少约1米/秒的速率在所述柔顺基底和所述成形结构之间喂入所述前体纤维网。
3.如前述任一项权利要求所述的方法，所述方法还包括在所述柔顺基底和所述成形结构之间施加压力并持续约0.5毫秒至约5秒的保压时间。
4.如前述任一项权利要求所述的方法，其中所述前体纤维网在所述方法期间的温度小于所述前体纤维网的熔点，优选低于所述前体纤维网的熔点至少约10℃。
5.如前述任一项权利要求所述的方法，其中所述柔顺基底包括选自由下列组成的组的材料：弹性体、毡、充液囊状物、充气囊状物、以及它们的组合。
6.如前述任一项权利要求所述的方法，其中所述柔顺基底具有约30硬度计至约80硬度计的肖氏硬度A。
7.如前述任一项权利要求所述的方法，其中所述成形结构的孔或凹陷具有约30微米至约640微米的平均边至边间距。
8.如前述任一项权利要求所述的方法，其中所述成形结构的孔具有约10微米至约5mm的平均宽度。
9.如前述任一项权利要求所述的方法，其中所述孔具有约25微米至约5000微米的深度。
10.如前述任一项权利要求所述的方法，其中所述离散的延伸元件具有开口远端。
11.如权利要求1至9中任一项所述的方法，其中所述离散的延伸元件具有闭合远端。
12.如前述任一项权利要求所述的方法，其中所述离散的延伸元件具有至少约0.2的纵横比。
13.如前述任一项权利要求所述的方法，其中所述外加压力为约1MPa至约100MPa。
14.如前述任一项权利要求所述的方法，其中所述离散的延伸元件相对于所述前体纤维网的厚度为薄化的。
15.如前述任一项权利要求所述的方法，其中所述外加压力足以将所述前体纤维网拉伸至超过其屈服点。
16.如前述任一项权利要求所述的方法，其中所述前体纤维网选自由下列组成的组：聚乙烯、聚丙烯、以及它们的组合。
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