CN102348550A - 具有密封件的制品及用于形成该制品的方法 - Google Patents

具有密封件的制品及用于形成该制品的方法 Download PDF

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Publication number
CN102348550A
CN102348550A CN2010800113620A CN201080011362A CN102348550A CN 102348550 A CN102348550 A CN 102348550A CN 2010800113620 A CN2010800113620 A CN 2010800113620A CN 201080011362 A CN201080011362 A CN 201080011362A CN 102348550 A CN102348550 A CN 102348550A
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CN
China
Prior art keywords
discrete
fleece
shaped structure
extending element
microns
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN2010800113620A
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English (en)
Inventor
K.J.斯通
R.D.扬
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Ltd
Procter and Gamble Co
Original Assignee
Procter and Gamble Ltd
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Filing date
Publication date
Family has litigation
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Application filed by Procter and Gamble Ltd filed Critical Procter and Gamble Ltd
Publication of CN102348550A publication Critical patent/CN102348550A/zh
Pending legal-status Critical Current

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    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24893Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
    • Y10T428/24901Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material including coloring matter
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
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    • Y10T428/24967Absolute thicknesses specified
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Abstract

本发明公开了一种具有压花密封件的制品,所述制品包括至少两个纤维网和接合所述至少两个纤维网的一部分的压花密封件,密封件包括在所述至少两个纤维网中形成的共配准的离散的同心延伸元件,离散的延伸元件具有开口近端。

Description

具有密封件的制品及用于形成该制品的方法
发明领域
本发明涉及一种具有压花密封件的制品和用于形成所述制品的方法。
发明背景
存在很多已知的暂时将薄的材料纤维网粘附在一起以形成密封件的方法,包括例如使用粘合剂、加装上机械扣紧元件诸如Velcro、以及通过热密封或热机粘结而在熔融状态中熔合所述纤维网。例如,美国专利5,462,166公开了通过热机方法应用热和压力将热塑性聚合物薄膜软化并熔合在一起。然而,这些方法为用于形成密封件的方法增添了不可取的成本和低效率以及复杂性。此外,在熔融状态中通过将纤维网熔合在一起而形成的密封件还可能在非密封件位置不可取地发生撕裂,并且会具有使用者所不喜欢的僵硬的塑料般密封件。此外,这些已知的密封方法还会产生如下的密封件,当所述两个纤维网被分离和密封件断开时,其可表现出相对大的噪声,例如,Velcro密封件断开时会发出特征性的大声音。
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具有密封件的制品的方法,所述密封件在断开时(即,当所述两个纤维网在密封件处分离时)声音极小。这对于用作女性护理产品的包装的制品来讲尤其如此。非常期望具有如下的密封包装,当打开此类包装时其产生极小的噪声甚至不产生噪声;从而允许使用者更加隐私地打开包装。
发明概述
在一个实施方案中,一种制品包括至少两个纤维网和接合所述至少两个纤维网的一部分的压花密封件。所述密封件包括具有开口近端的离散的同心延伸元件,所述延伸元件被在所述至少两个纤维网中形成的平地(land)所围绕。离散的延伸元件的一些部分可具有薄于平地的厚度。例如,离散的延伸元件的远端和/或侧壁相对于平地可为薄化的。所述共成形的纤维网的离散的同心延伸元件为套叠的并且可具有大面间表面积。
在另一个实施方案中,一种方法包括在压力源和成形结构之间喂入至少两个纤维网,所述成形结构包括选自由下列组成的组的多个离散的成形元件:离散的孔、离散的凹陷、离散的突起元件、以及它们的组合。该方法还包括从压力源顶靠纤维网和成形结构施加压力,所述压力足以使所述至少两个纤维网适形于成形结构的离散的成形元件,从而形成包括具有开口近端的多个离散的同心延伸元件的压花密封件。
附图简述
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。附图中没有一个是按比例绘制的。
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2A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2B为具有离散的突起元件的成形结构的一部分的放大透视图;
图3A为根据本公开的一个实施方案的压花密封件的扫描电子显微(SEM)图像;
图3B为图3A的压花密封件的放大的SEM图像;
图4为根据本公开的一个实施方案的压花密封件的一部分的剖面图;
图5为根据本公开的一个实施方案的压花密封件的一部分的透视图,所述部分具有包括开口远端的离散的延伸元件;
图6为根据本公开的一个实施方案的方法的示意图,示出了静态气体压力充气室;
图7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;并且
图8为可用于根据本公开的一个实施方案的方法的具有离散的延伸元件的成形结构的侧视图的高放大率光学显微图像。
发明详述
本文公开了一种制品和用于形成所述制品的方法,所述制品具有粘附至少两个纤维网的一些部分的密封件,并且所述方法克服了现在技术的前述缺点中的一个或多个缺点。具体地讲,所述制品的实施方案现在使如下制品成为可能:在分离所述至少两个纤维网时,所述制品大体上声音更小。该方法的实施方案现在使一种更高效的纤维网密封方法成为可能。例如,所述制品和方法的实施方案现在能够避免使用昂贵的粘合剂或附加机械粘附元件诸如钩/环(即Velcro)和脊/槽、以及与施用粘合剂或机械粘附元件相关联的复杂方法。所述制品和方法的实施方案也能够避免使用将所述两个纤维网熔融并熔合在一起以形成密封件的复杂方法。此类密封件在分离时可能声响很大和/或导致纤维网撕裂(而不是在密封件处分离)。
参见图3A和3B,在一个实施方案中,所述制品一般包括至少两个纤维网层和接合所述至少两个纤维网层的一些部分的压花密封件16。所述密封件包括离散的同心延伸元件22,所述延伸元件被在所述至少两个纤维网34中形成的平地13所围绕。离散的延伸元件22相对于平地13可为薄化的。例如,离散的延伸元件22的远端和/或侧壁可为薄化的。所述共成形的纤维网的离散的同心延伸元件为套叠的并且具有大面间表面积。
离散的延伸元件22在z方向上延伸以形成三维的共成形元件。据信离散的同心延伸元件22产生高剪切强度,从而防止所述至少两个纤维网在制品的操纵期间发生分离。令人惊讶的是,甚至在没有粘合剂、附加机械粘附元件或纤维网的熔融熔合的情况下,密封件也可具有极高的剥离强度。
不受理论的约束,据信压花密封件16的强度取决于以下因素:所述至少两个纤维网的套叠的共成形区域的大面间表面积、所述至少两个纤维网34的粘附到它们自身上和粘附到彼此上的能力、以及压花密封件16可被变形的容易程度。当压花密封件16包括具有闭合远端的离散的延伸元件22时,还据信在离散的同心延伸元件22之间会产生真空,所述真空产生将纤维网34保持在一起的吸力,从而增加压花密封件16的剥离强度。
所述至少两个纤维网的面间表面积取决于至少离散的延伸元件22的几何形状和压花密封件16中的离散的延伸元件22的密度。据信压花密封件16的剥离强度随着面间表面积的增加而增加。
所述至少两个纤维网34的粘附到它们自身上和粘附到彼此上的能力取决于至少以下因素:纤维网的摩擦系数、纤维网的表面能、以及所述两个纤维网之间的和/或相同纤维网的接触部分之间的吸引力诸如范德瓦尔斯力、偶极-偶极相互作用、静电力、氢键等。据信压花密封件16的剥离强度一般随着所述至少两个纤维网34粘附到它们自身上和粘附到彼此上的能力的增加而增加。
还据信,如果压花密封件16更具柔性而不是刚性,则剥离强度增加。对于更柔性的压花密封件,所述至少两个纤维网34可移动并挠曲在一起,因此当被挠曲时在共成形区域中保持紧密接触。据信当使用较低模量和/或较低规格的前体纤维网时,产生更柔性的密封件。如果压花密封件16为刚性的,则当被挠曲时所述至少两个纤维网34可更易于分离,并且此类分离可弱化压花密封件16的剥离强度。
形成压花密封件16的方法一般包括在压力源和成形结构10之间喂入至少两个纤维网,所述成形结构包括多个离散的成形元件11。成形元件11可包括例如离散的突起元件15、离散的孔12、离散的凹陷14、或它们的组合。该方法还包括从压力源顶靠所述至少两个纤维网和成形结构10施加压力,所述压力足以使所述至少两个纤维网的部分适形于离散的成形元件11,从而形成压花密封件16。压花密封件16包括具有开口近端的多个离散的同心延伸元件22。下文更详细地描述了所述制品和方法的这些方面。
成形结构
参见图1和图2,适用于本公开的方法的成形结构10包括多个离散的成形元件11。离散的成形元件11可包括离散的突起元件15、离散的孔、离散的凹陷、或它们的组合。成形结构10还可包括完全围绕离散的成形元件11的平地。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的离散的成形元件11可在尺度上较小。本公开的方法可生产出包括具有薄化远端24和/或侧壁的相对高纵横比的延伸元件11的压花密封件,甚至在不加热纤维网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2A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,所述直径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10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。孔12和凹陷14可具有约10微米至约500微米,或约25微米至约5000微米的深度。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可具有大体上等于纤维网中的至少一个的厚度,为至少两倍的纤维网中的至少一个的厚度,或为至少三倍的纤维网中的至少一个的厚度的深度。优选地,孔12和凹陷14具有为至少三倍的纤维网的总厚度的深度。
成形结构10的纤维网接触表面上的孔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的纤维网接触表面测量到孔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。
离散的突起元件15可具有至少约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,或至少约380微米的高度。离散的突起元件15可具有直径,就大致圆柱形结构而言,所述直径为外径。就突起元件15的非均匀横截面、和/或非圆柱形结构而言,将直径dp测量为突起元件15的在突起元件15的1/2高度hp处的平均横截面尺寸,如图2B所示。离散的突起元件15可具有直径dp,所述直径可为约10微米至约5,000微米,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。在一个实施方案中,成形结构10的离散的突起元件15将具有小于约500微米的直径。
对于每个突起元件15,可确定被定义为hp/dp的突起元件纵横比。突起元件15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。一般来讲,由于各个突起元件15的实际高度hp可有变化,因此多个突起元件15的平均高度(“hpavg”)可通过确定成形结构10的预定区域上的突起元件的平均最小振幅(“Apmin”)和突起元件的平均最大振幅(“Apmax”)来确定。同样,对于变化的横截面尺寸,可针对多个突起15来确定平均突起直径(“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,诸如通过计算机辅助扫描显微术和相关的数据处理来进行。因此,就成形结构10的预定部分而言,突起元件15的平均纵横比(“ARpavg”)可被表示为hpavg//dpavg
成形结构10的离散的突起元件15可具有远端24,所述远端为平坦的、圆化的或尖锐的,这取决于是否期望所生产出的压花密封件16具有包括开口的(在成形结构10上需要更尖锐的突起元件)或闭合的(在成形结构10上需要更圆化的突起元件)远端24的离散的延伸元件22。成形结构10的离散的突起元件15的圆化远端24可具有某种尖端半径,诸如约5微米至约150微米,约10微米至约100微米,约20至约75微米,或约30微米至约60微米。
离散的突起元件15的侧壁可为完全竖直的或可为锥形的。在一个实施方案中,离散的突起元件15具有锥形的侧壁,因为锥形的侧壁可影响压力源的耐久性和使用寿命。例如,当使用柔顺基底44时,锥形的侧壁可便于柔顺基底44在其适形在成形结构10的离散的成形元件11周围时减轻柔顺基底44上的压缩或张紧。这也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°,约2°至约30°,或约5°至约25°的锥度。
在一个实施方案中,成形元件可具有变化的几何形状,诸如突起元件15的高度和孔12或凹陷14的深度,所述几何形状可选择性地影响材料纤维网的某些区域的粘结强度。例如,成形元件的高度可逐渐增加或在数十个或数百个相邻突起元件的范围内逐渐增加,这可导致具有包括变化的高度的离散的延伸元件22的纤维网,继而可导致具有强度梯度的压花密封件16。可调整导致离散的延伸元件22的对应特征的成形结构的其他特征,以形成具有强度梯度的压花密封件16。例如,成形结构可包括具有面密度梯度的成形元件。
在一个实施方案中,突起元件可为球形、椭球形、雪人形,它们沿突起元件的高度具有不同的或变化的直径。
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10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40微米至约2,000微米的直径。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10微米至约5000微米,约50微米至约5000微米,约500微米至约5000微米,或约800微米至约2,500微米。
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34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的离散的成形元件11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。在另一个实施方案中,离散的突起元件15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延伸的突起元件。例如,当成形结构10呈辊形式时,可围绕所述辊的整个圆周形成凹槽和/或延伸的突起元件。所述凹槽和/或延伸的突起元件可为大体上直的(例如,一致地平行于所述辊的边缘)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4个离散的成形元件11/平方厘米,至少约10个离散的成形元件11/平方厘米,至少约95个离散的成形元件11/平方厘米,至少约240个离散的成形元件11/平方厘米,约350至约10,000个离散的成形元件11/平方厘米,约500至约5,000个离散的成形元件11/平方厘米,或约700至约3,000个离散的成形元件11/平方厘米。
离散的成形元件11可具有约30微米至约1000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微米的两个相邻孔12或凹陷14之间的平均边缘至边缘间距。
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成形元件11,而成形结构10的其他部分(或区域)可不包括离散的成形元件11。不具有离散的成形元件11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的离散的成形元件11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成形元件11的区域和/或具有离散的成形元件11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,以便压花密封件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。例如,压花密封件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的平均深度或离散的突起元件15的平均高度对纤维网34中的至少一个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,以确保纤维网34受到足够的拉伸以便各自被永久地变形以产生压花密封件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离散的成形元件11以制造出压花密封件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,离散的成形元件11与成形结构10整体地制成。即,通过除去材料或积聚材料将成形结构10制成为整合结构。例如,具有所需的相对小尺度的离散的成形元件11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10一般可根据美国专利4,342,314的教导通过光蚀刻层压体方法来构造。
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 BDA0000090644320000091
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和/或离散的突起元件15。
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,以生产出本发明的压花纤维网,其中活化带为坚实基底或柔顺基底。
如果成形结构10包括突起元件15以及离散的孔12和凹陷14,则离散的延伸元件22可在纤维网34中形成,所述延伸元件从纤维网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,可产生两面的压花密封件16,在压花密封件16的每个侧面上具有不同图案或尺寸的延伸元件22。取决于在成形结构10和柔顺基底44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,压花密封件16的离散的延伸元件22可具有闭合远端或开口远端24。
压力源
用来提供顶靠成形结构10的力的压力源可为例如柔顺基底44、静压充气室、速度压力源、或它们的组合。适用于提供速度空气压力以使前体纤维网适形于成形结构的装置的一个实例为高压气刀。高压气刀可从例如Canadian Air Systems商购获得。利用空气压力使前体纤维网适形于成形结构的合适的装置和方法的另一个实例描述于美国专利5,972,280中。适用于提供水压以使前体纤维网适形于成形结构的装置的一个实例为水充气室,诸如美国专利7,364,687所述的水充气室。
例如,一种合适用于制造压花密封件16的方法为液压成形法。液压成形法的非限制性实例描述于美国专利4,609,518和美国专利4,846,821中。可将如本文所述的成形结构和纤维网用于此类液压成形法。
另一种合适的例如用于制造压花密封件16的方法为真空成形法。真空成形法的非限制性实例描述于美国专利4,456,570和4,151,240、以及美国专利申请公布2004/0119207 A1中。可将如本文所述的成形结构和前体纤维网用于此类真空成形法以生产出本公开的压花密封件16。其他合适的方法描述于美国专利4,846,821和美国专利申请公布2004/0119207 A1中。
柔顺基底
参见图7,在最低限度上,柔顺基底44的外表面(即,柔顺基底44的朝成形结构10取向的表面)包括柔顺材料46。例如,柔顺基底44可包括用柔顺材料46覆盖的刚性材料48。刚性材料48可为金属(诸如钢)、塑料、或显著地硬于柔顺材料46的任何其他材料。覆盖刚性材料48的柔顺材料46的厚度通常将不大于约26mm,并且优选约1mm至约26mm,更优选约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46制成。
柔顺基底44或柔顺材料46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44为多孔弹性体。柔顺基底44或柔顺基底44中所用的柔顺材料46优选地具有弹力特性(诸如压缩恢复)使得柔顺材料46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44或柔顺基底44中所用的柔顺材料46优选地也具有足够的耐久性以压花大量的纤维网34材料。因此,柔顺基底44优选地具有合适的韧度和耐磨度,其中在该方法期间柔顺基底44将趋于被成形结构10磨蚀。
柔顺基底44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44为用柔顺材料46诸如弹性体覆盖的金属辊。在另一个实施方案中,柔顺基底44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44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44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44辊具有与成形结构10辊的直径相同的直径。
柔顺基底44或柔顺基底44中所用的柔顺材料46通常将具有约30至约90硬度测验器,优选地约35至约80硬度测验器,并且更优选地约40至约70硬度测验器的按肖氏硬度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硬度测验器诸如得自PTC Instruments(LosAngeles,California)的型号为306的A型经典式硬度测验器来确定。应当认识到,柔顺基底44可表现出变化的硬度,例如靠近柔顺基底44的外表面的较低硬度和朝内表面的较高硬度(即在柔顺基底44的z方向上变化的硬度)或在柔顺基底44的外表面上变化的硬度(即在柔顺基底44的x-y平面中变化的硬度)。
柔顺基底44中所用的柔顺材料46通常将具有约1至约20MPa,优选约2至约18MPa,并且更优选约3至约10MPa的拉伸模量。柔顺材料46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(以商品名得自DuPont)、氯丁二烯橡胶、降冰片橡胶、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 BDA0000090644320000112
它们具有约40至约70硬度测验器的肖氏硬度A。
柔顺材料46也可为诸如吸收芯之类的材料,所述材料可与纤维网34一道在刚性材料48和成形结构10之间喂入。这种材料可用来产生顶靠纤维网34和成形结构10的压力以便压花所述纤维网34。然后可将这种材料与与压花密封件16一道结合到成品消费品诸如妇女卫生制品中。
柔顺基底44可任选地包括凹进区域,所述凹进区域的深度足以防止纤维网34在特定区域中压花或在特定区域中仅最低程度地压花所述纤维网34。
静压充气室
参见图6,利用静压充气室36来提供顶靠纤维网34的力以使纤维网34适形于成形结构10的离散的成形元件11。优选地,静压充气室36为静态气体压力充气室。所述气体可为空气、氮气、二氧化碳、以及它们的组合。
静压充气室36向纤维网34上施加压力。静态气体压力充气室36可包括护罩38,所述护罩限定邻近纤维网34的充气室40。护罩38可包括至少一个高压气体入口42,所述入口允许高压气体或其他流体进入护罩38从而产生静压条件。在静态气体压力条件下,不存在如同速度压力源诸如气刀的情况一样的对未压花的纤维网34进行冲击的速度和密度。相反,在护罩38中保持着静态高气体压力,所述压力在纤维网上在纤维网34的面向静压充气室36的表面和纤维网34的面向成形结构10的表面之间产生压力差。所述压力差足以使纤维网34适形于成形结构10的离散的成形元件11。可例如通过向纤维网34的面向成形结构10的表面上施加真空来增强所述压力差。
纤维网
至少两个纤维网层由压花密封件16来接合。所述至少两个纤维网可为例如相同纤维网的不同的重叠部分。例如,材料纤维网可为折叠的,例如呈三折构型,并且材料纤维网的重叠部分可由压花密封件16来接合。作为另外一种选择,所述至少两个纤维网可为不同的纤维网。合适的纤维网包括如下的材料,所述材料可被压力源变形,使得纤维网适形于成形结构10的离散的元件11以生产出接合所述两个纤维网的压花密封件16。优选地,纤维网具有粘附到它们自身和/或其他材料纤维网上的能力。
纤维网通常包含合成材料、金属材料、生物材料(具体地讲,动物衍生材料)、或它们的组合。所述至少两个纤维网可为相同的材料或可为不同的材料。纤维网可任选地包含纤维素材料。在一个实施方案中,纤维网不含纤维素材料。合适的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、箔诸如金属箔(例如铝、黄铜、铜等)、包含供应充足的聚合物的纤维网、泡沫、包括合成纤维(例如
Figure BDA0000090644320000131
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。合适的纤维网还包括这些材料的层压体或共混物。
如果纤维网为纤维质纤维网,则所述纤维质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 BDA0000090644320000132
在一个实施方案中,纤维网为聚合物薄膜。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含聚合物的共混物或混合物。
在某些实施方案中,纤维网可包含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。
压花之前的每一纤维网的厚度通常将在约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。
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。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的共混物形成的纤维网具有约110℃至约122°的熔点。由聚丙烯形成的纤维网具有约165℃的熔点。由聚酯形成的纤维网具有约255℃的熔点。由尼龙6形成的纤维网具有约215℃的熔点。由PTFE形成的纤维网34具有约327℃的熔点。
在一个实施方案中,该方法在小于纤维网的熔点的温度下进行。例如,该方法可在比纤维网的熔点低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,该方法在大于纤维网的玻璃化转变温度的温度下进行。无论该方法中所用的温度如何,在总体上将工艺条件选择成使得不会熔融熔合纤维网。例如,较高的温度可与短的保压时间相配合,使得所述至少两个材料纤维网不会熔融而导致纤维网的熔合。
任选地,在该方法中,在压花之前可增塑纤维网34以减小弹性模量和/或降低它们的脆性。
在一个实施方案中,纤维网34为应变硬化的。可期望纤维网的应变硬化特性有利于纤维网适形于成形结构10的离散的成形元件11。这可优选地用于生产压花密封件,其中期望具有压花密封件16的延伸元件22的闭合远端24。
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密封件16。所述至少两个纤维网34中的至少一个通常将具有屈服点,并且纤维网34优选地被拉伸超过其屈服点以形成压花密封件16。即,纤维网34应当具有足够的屈服特性使得纤维网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的压花密封件的情形中,产生破裂以形成开口远端24。如下所述,工艺条件诸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,从而形成具有所期望的离散的延伸元件22的压花密封件16。因此,一般来讲,已发现优选的要用作纤维网34的起始材料表现出低屈服和高伸长特征。此外,如前所述,纤维网还优选地为应变硬化的。适于用作纤维网34的薄膜的实例包括包含以下物质的薄膜:低密度聚乙烯(LDPE)、线性低密度聚乙烯(LLDPE)、聚丙烯、以及它们的共混物。
纤维网34也应当为足够可变形的并具有足够的用作纤维网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密封件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。
纤维网34可各自为两个或更多个纤维网层的层压体,并且可为共挤出的层压体。例如,每个纤维网均可包括两个层,并且每个纤维网均可包括三个层,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,纤维网中的至少一个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。
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,则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,在压花密封件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的能力会受到纤维网34的厚度的限制。
在某些实施方案中,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,则初始时共混到纤维网中的表面活性剂的含量可多达按总纤维网的重量计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,一般为或低于总纤维网的约5%重量的含量加入。
在各种实施方案中,纤维网也可包含添加剂以增强纤维网的粘附到其自身上和其他纤维网上的能力。可使用用于增加纤维网的粘合能力的任何已知的添加剂。例如,可将低分子量聚合物例如聚异丁烯(PIB)和聚(乙烯-乙酸乙烯酯)(EVA)共聚物加入到材料纤维网中。例如,当用于LDPE时,PIB和EVA具有容易地与彼此相互作用的链,并且它们的较低分子量使得它们在宿主聚合物基质内更具活动性。
优选地,纤维网在纤维网的表面上不含剥离剂和/或低表面能化学官能团。已发现在纤维网的表面上存在低表面能化学官能团可降低纤维网的粘结强度。例如,局部地施加到要粘结的纤维网表面中的一个或多个上的硅氧烷粘合剂剥离剂可使得所得粘结变弱,尤其是与在没有局部地施加硅氧烷粘合剂剥离剂的相同材料纤维网中所形成的粘结相比,更是如此。据信纤维网表面之间的吸引力被低表面能处理剂减弱。其他低表面能表面处理剂包括碳氟化合物。
在某些实施方案中,纤维网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密封件16的不透明度。二氧化钛可按纤维网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,例如炭黑、氧化铁、云母、碳酸钙(CaCO3)、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,当用于接触皮肤的应用时,包含颗粒物质的压花密封件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以允许当压花密封件16用于接触皮肤的应用时皮肤直接接触到此类皮肤护理剂。
如果用于纤维网34,则颗粒材料的平均粒度通常将为0.1微米至约200微米,0.2微米至约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密封件16的视觉外观。
纤维网也可任选地包含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,以改善压花密封件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。
纤维网也可任选地包含填料、增塑剂等。
压花纤维网
具有压花密封件16的制品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。压花密封件16包括离散的同心延伸元件22。如本文所用,术语“同心”是指延伸元件22具有大体上相同的中心。例如,延伸元件的中心可偏移小于约1000微米,小于约500微米,小于约100微米,小于约50微米,或小于约20微米的量。在一个实施方案中,离散的延伸元件22的一部分相对于围绕离散的延伸元件22的平地13为薄化的。例如,离散的延伸元件22的远端和/或侧壁相对于平地13可为薄化的。离散的同心延伸元件22具有所述至少两个纤维网的套叠的共成形区域的大面间表面积。此外,如上所述,据信存在足够的摩擦力和/或吸引力以保持所述至少两个纤维网接合在压花密封件16处。就具有闭合远端24的离散的延伸元件22而言,其他吸力可有助于保持所述至少两个薄膜接合在压花密封件16处。所述两个纤维网在压花密封件16处的分离需要足够的力来分离离散的同心延伸元件22。与现有技术的粘结方法诸如涉及通过热和压力来熔合纤维网的那些方法相比,此类分离产生极小噪声甚至不产生噪声。当制品的所述至少两个层在压花密封件16处分离时,由所述分离所产生的噪声显著地小于由通过热机粘结方法诸如美国专利5,462,166所述的方法形成的常规密封件所产生的噪声。例如,当制品的所述至少两个层在压花密封件16处分离时,由所述分离所产生的声压级可小于约70dB,小于约65dB,或小于约60dB,所述声压级通过“声压级试验”来测量。压花密封件16在分离时声音大体上小于通过使用常规加工条件例如美国专利5,462,166中所述的那些条件的常规热机粘结方法所形成的密封件。例如,压花密封件16在分离时可产生如下的声压级,所述声压级比通过常规热机粘结方法形成的密封件所产生的声压级小至少约2dB,至少约3dB,至少约4dB,至少约5dB,至少约6dB,至少约7dB,至少约8dB,至少约9dB,或至少约10dB,所述通过常规热机粘结方法形成的密封件具有与压花密封件16大体上相同的剥离强度并且在与压花密封件16相同的条件下分离。大体上相同的剥离强度是指剥离强度在压花密封件16的剥离强度的至少约50%,至少约60%,至少约70%,或至少约80%以内。
压花密封件16可具有至少大体上等于常规密封件诸如常规热机密封件的剥离强度的剥离强度,所述剥离强度通过“剥离强度试验”来测量。例如,压花密封件16可具有的剥离强度至少在常规热机密封件的剥离强度的30%,40%,50%,60%,70%,80%,90%,或100%以内。
“剥离强度试验”可根据美国专利5,462,166所公开的方法来进行。
“声压级试验”可用QUEST Technologies的型号为2900的测声计来进行以测量并记录声压级,在此期间剥离开具有已知宽度和长度的粘结的纤维网。将测声计的麦克风放置成与要剥离开的粘结处相距5cm。使用A权重因子来操作测声计以更精密地逼近人耳的听声方式。(标准IEC 651-声级计。该标准得自International Electrotechnical Commission。附加测量参数为范围:40-100dB;交换速率:3dB;时间常数:快;阈值:关;以及峰值权重:C。
改进了在美国由The Procter & Gamble Company(Cincinnati,Ohio)出售的以三折构型粘结的具有防粘纸和外塑料包裹物的Always最大号护垫以进行所述实施例的声压级测量。将所述商业护垫的外包裹物和防粘纸替换成具有通过本公开的方法形成的压花密封件16的测试薄膜。在形成压花密封件16之前,将2″宽的管道胶带连结到外塑料包裹物和护垫每端的顶片。所述胶带覆盖约最后1″的护垫端部。在护垫的每端上,将胶带的粘合剂侧连结到彼此上以产生用于拉伸的安装突出部。在将管道胶带连结到开口护垫之后,随后将外包裹物往回粘结成所述三折构型。然后在剥离强度拉伸之前,将安装突出部夹紧到Instron夹具中。
将纤维网定位在成形结构10和压力源之间,并且施加压力以使纤维网34适形于成形结构10的离散的成形元件11。参见图3A和3B,从而生产出具有包括离散的同心延伸元件22A和22B的压花密封件16的制品。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所示)和/或闭合(如图3A和3B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密封件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。
从至少两个纤维网生产出了三维的压花密封件16。每个纤维网可为单层的材料纤维网或多层的共挤出的材料纤维网或层压材料纤维网,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。
离散的延伸元件22被成形为每一纤维网的突起延伸部,一般位于其第一表面26上。每一纤维网的离散的延伸元件22为同心的。因此,外纤维网的离散的延伸元件可具有略微大于内纤维网的离散的延伸元件的直径,使得内纤维网的离散的延伸元件驻留在外纤维网的离散的延伸元件内,即,离散的延伸元件为套叠的。压花密封件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粘结强度、柔软感和视觉效应来预定。据信离散的同心延伸元件22之间的紧密接触的大面间表面积随着每单位面积上的离散的延伸元件22的高度、直径、纵横比、和/或数目的增加而增加。还据信面间表面积的增加导致压花密封件16的粘结强度的对应的增加。
参见图4,离散的延伸元件22可被描述为从压花密封件16的第一表面26突起。因此,离散的延伸元件22可被描述为与纤维网成一整体,并且通过永久地局部塑性变形纤维网来形成。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22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22通常将具有与纤维网的厚度至少相同的高度,或至少2倍的纤维网的厚度、或优选地至少3倍的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。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可通过确定压花密封件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22来确定平均直径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,压花密封件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帮助确保压花密封件16可容易地从成形结构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。
纤维网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,可在或靠近离散的延伸元件的闭合远端或开口远端24和/或沿侧壁观察到薄化。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密封件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、和纤维网在或靠近远端24和/或侧壁的壁的薄化,离散的延伸元件22会对由人的手指施加在压花密封件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。
纤维网在或靠近闭合远端或开口远端24和/或侧壁的薄化可相对于压花之前的纤维网的厚度或相对于完全围绕压花密封件16的离散的延伸元件22的着陆区域的厚度进行测量。纤维网通常将相对于纤维网的厚度表现出至少约25%,至少约50%,或至少约75%的薄化。纤维网通常将相对于围绕压花密封件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,所述制品包括压花密封件16,所述压花密封件在其至少一个表面上表现出柔软且丝般触觉印象,压花密封件16的丝感表面表现出离散的同心延伸元件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。在某些实施方案中,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。
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,并且压花密封件16通常将包括约4至约10,000,约10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5,000微米,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。
用于制造压花密封件的方法
用于形成压花密封件16的方法包括在压力源和成形结构10之间喂入所述至少两个纤维网,并且从压力源顶靠纤维网和成形结构10施加压力,所述压力足以使纤维网的部分适形于成形结构10的离散的成形元件11从而形成具有离散的同心延伸元件22的压花密封件16。取决于所产生的压力和成形结构10的外形,纤维网对成形结构10的适形可为局部适形、基本适形、或完全适形。不受理论的约束,据信开口远端24可通过在使纤维网适形于成形结构10的离散的成形元件11的同时局部地破裂纤维网来形成。
为了永久地变形纤维网以形成压花密封件16,所施加压力一般足以将纤维网拉伸超过它们的屈服点。
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和压力源之间的所述至少两个材料纤维网的单个片。
连续方法可涉及提供所述至少两个材料纤维网的辊,将所述辊退绕并且在成形结构10和压力源之间喂入。所述至少两个材料纤维网也可布置在单一辊上。成形结构10可例如呈辊的形式。随着纤维网34从成形结构10辊和压力源之间穿过,形成压花密封件16。如果压力源为柔顺基底44,则柔顺基底44也可呈辊的形式。
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”是指压力被施加到纤维网的给定部分上时的时间量,通常所述时间量用于使纤维网的给定部分定位在成形结构10和压力源之间。通常将压力施加到纤维网上并持续小于约5秒,小于约1秒,小于约0.5秒,小于约0.1秒,小于约0.01秒,或小于约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密封件。因此,本公开的方法使得能够高速地生产压花密封件。
纤维网可按至少约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和压力源之间喂入。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上的离散的延伸元件22的形状和所施加的压力之类的因素,所生产出的压花密封件16的延伸元件22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、压力源、和/或纤维网。然而,应当认识到,会由于成形结构10和压力源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/或压力源以便将工艺条件保持在所期望的温度诸如环境温度。
该方法也可用具有高温的纤维网来进行。例如,纤维网的温度可小于纤维网的熔点。例如,纤维网的温度可比纤维网的熔点低至少约10℃。纤维网在该方法期间可具有约10℃至约200℃,约10℃至约120℃,约20℃至约110℃,约10℃至约80℃,或约10℃至约40℃的温度。纤维网在该方法期间可通过如下方式来加热:使用加热的压力源例如用于静压充气室36的加热的流体压力源或加热的柔顺基底44来加热纤维网、和/或加热成形结构10。例如,加热的气体可用作用于静压充气室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,测量压力源和成形结构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PaperThermometer Company的温度标贴来确定。
压力源提供平均压力。所述平均压力足以迫使定位在成形结构10和压力源之间的纤维网适形于成形结构10的离散的成形元件11以形成压花密封件16。一般来讲,在成形结构10和静压充气室36之间提供的或由速度压力源提供的平均压力为约0.1MPa至约25MPa,约0.5MPa至约20MPa,约0.7MPa至约10MPa,约1MPa至约7MPa,约1MPa至约20MPa,约0.5MPa至约10MPa,约10MPa至约25MPa,或约0.5MPa至约5MPa。一般来讲,在成形结构10和柔顺基底44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,所施加压力可为至多约30MPa。
当将柔顺基底44用作压力源时,通过向成形结构10和/或柔顺基底44施加力将成形结构10和柔顺基底44按压至期望的压缩距离。“压缩距离”通过测量成形结构10被挤压到柔顺基底44中的距离来确定。该距离可通过如下方式来测量:使成形结构10和柔顺基底44初始地接触,然后迫使成形结构10和柔顺基底44结合在一起。初始接触之后的成形结构10和柔顺基底44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44两者均为辊,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44的旋转轴线之间的距离的变化。
成形结构10和柔顺基底44的压缩距离通常将为约0.1mm至约5mm,约0.2mm至约4mm,或约0.3mm至约3mm。
该方法还可任选地包括在成形结构10和压力源之间提供纤维网之前向纤维网和/或成形结构10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,以减小纤维网和成形结构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。
该方法可任选地与其他方法相组合以进一步操纵具有压花密封件16的纤维网。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用于吸收制品的包装。
该方法还可包括从第二压力源来施加压力。第二压力源可相同于或不同于第一压力源,并且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44。由第二压力源施加在纤维网上的压力通常将类似于由前文所述的第一压力源施加在纤维网34上的那些压力。例如,该方法可包括使用多个静压充气室。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10和第一静压充气室之间将压力施加在纤维网34的第一部分上。然后可在成形结构10和第二静压充气室之间将压力施加在纤维网34的第一部分上以使纤维网34的第一部分进一步适形于相同成形结构10的相同突起元件、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。
制品的用途
所述制品可用于许多不同的方面,包括用作吸收制品的包装材料、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
使用两个纤维网来形成具有压花密封件16的制品。第一纤维网为获自Engelhard Corporation(Iselin,NJ)的虹彩薄膜Aurora Special Effect FilmFluoridescent TM Groovey Green FG 8601 RG-56。第二纤维网为三层的共挤出的纤维网,其具有80%LLDPE和20%LDPE。压花方法在室温下进行。成形结构10包括多个突起元件。离散的突起元件为大致柱状的,具有圆形横截面形状。离散的突起元件的侧壁具有小的向内锥度。突起元件的远端具有相对圆化的顶端。突起元件具有约192微米的高度,并且被布置成具有约254微米的中心至中心间距的六边形阵列。成形结构10的高放大率侧视图示于图8中。
压力源为具有柔顺材料46的柔顺基底44,所述柔顺材料呈6.4mm厚的40硬度测验器的天然橡胶片形式。将所述两个纤维网在成形结构10和柔顺基底44之间喂入,并且施加约15MPa(2,200psi)的压力使纤维网适形于成形结构10的突起元件15,从而形成具有离散的同心延伸元件22的压花密封件16。图3A和3B示出了所形成的压花密封件16。
实施例2
使用获自RKW US,Inc.的两个聚乙烯薄膜形成了具有压花密封件16的制品,所述薄膜各自为约15微米厚,具有14.2克/平方米(“gsm”)的基重。在该方法中使用7mm厚的
Figure BDA0000090644320000251
橡胶(获自Perma-Flex RollerTechnology(Salisbury,North Carolina)的HYPALON CHECKMATE HGS-HT)的柔顺基底。柔顺基底为两层的层压体,所述层压体由具有约53的肖氏硬度A的4mm厚的
Figure BDA0000090644320000252
片和具有85的肖氏硬度A的3mm厚的
Figure BDA0000090644320000253
片制成。柔顺基底呈15mm×15mm的正方形片的形式。在压花方法期间,所述层压体的4mm厚的
Figure BDA0000090644320000254
(53的肖氏硬度A)部分接触纤维网。成形结构为约1mm厚的金属,并且在六边形阵列中具有中心至中心地隔开0.25mm的0.18直径的凹陷。这些凹陷具有圆形横截面,它们的侧壁为直的。通过如下方式使这些凹陷通气:在凹陷的底部表面中包括开口以允许空气在压花方法期间从背面逸出。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申请公布2009/0120308 A1中,并且被设计成模拟形成压花密封件16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6m/s的模拟速率在成形结构10和柔顺基底之间喂入纤维网。
下表列出了柔顺基底和成形结构之间的压缩距离、所施加压力、和力以及压花密封件的离散的延伸元件22的平均高度。
Figure BDA0000090644320000261
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在相关部分均以引用方式并入本文中。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。
尽管已用特定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,在不背离脱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改变和变型。

Claims (16)

1.一种制品,所述制品包括:
至少两个纤维网;和
接合所述至少两个纤维网的一部分的压花密封件,所述密封件包括离散的同心延伸元件,所述延伸元件被在所述至少两个纤维网中形成的平地(land)围绕,所述离散的延伸元件具有开口近端,并且所述离散的延伸元件的部分具有小于所述平地的厚度的厚度。
2.如权利要求1所述的制品,其中所述压花密封件不含粘合剂。
3.如前述权利要求中的任一项权利要求所述的制品,其中所述离散的同心延伸元件不是通过熔融而熔合在一起的。
4.如前述任一项权利要求所述的制品,其中所述离散的延伸元件的远端和/或侧壁相对于所述平地薄化了至少约25%。
5.如前述任一项权利要求所述的制品,其中至少两个纤维网选自由下列组成的组:聚丙烯、聚乙烯、以及它们的组合。
6.如前述任一项权利要求所述的制品,所述制品还包括邻近所述压花密封件设置的未密封部分,所述未密封部分包括基本上不含离散的同心延伸元件的所述至少两个纤维网的部分。
7.如权利要求5所述的制品,其中所述压花密封件沿所述至少两个纤维网的相对两侧设置,并且所述未密封部分设置在具有所述压花密封件的相对两侧之间。
8.一种方法,所述方法包括:
在压力源和成形结构之间喂入至少两个纤维网,所述成形结构包括选自由下列组成的组的多个离散的成形元件:离散的孔、离散的凹陷、离散的突起元件、以及它们的组合;并且
从所述压力源顶靠所述纤维网和所述成形结构施加压力,所述压力足以使所述至少两个纤维网适形于所述成形结构的离散的成形元件以形成包括具有开口近端的多个离散的同心延伸元件的压花密封件。
9.如权利要求8所述的方法,其中所述压力源选自由下列组成的组:静压充气室、柔顺基底、速度压力源、以及它们的组合。
10.如权利要求8或9中任一项所述的方法,其中所施加压力为约1MPa至约100MPa。
11.如权利要求8至10中任一项所述的方法,所述方法包括施加压力并持续约0.5毫秒至约50毫秒的保压时间。
12.如权利要求8至11中任一项所述的方法,其中所述纤维网在所述方法期间的温度小于所述纤维网的熔点,优选地比所述纤维网的熔点低至少约10℃。
13.如权利要求8至12中任一项所述的方法,其中所施加的压力足以将所述纤维网拉伸超过所述纤维网的屈服点。
14.如权利要求8至13中任一项所述的方法,其中所述纤维网选自由下列组成的组:聚丙烯、聚乙烯、以及它们的组合。
15.如权利要求8至14中任一项所述的方法,其中所述压花密封件不含粘合剂。
16.如权利要求8至15中任一项所述的方法,其中所述压花密封件不是通过将所述纤维网在熔融状态下熔合在一起而形成的。
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CN109310538B (zh) * 2016-07-29 2019-11-05 尤妮佳股份有限公司 吸收性物品
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