CN102933375A - 接缝结构及制备接缝的方法 - Google Patents

接缝结构及制备接缝的方法 Download PDF

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Publication number
CN102933375A
CN102933375A CN2011800281565A CN201180028156A CN102933375A CN 102933375 A CN102933375 A CN 102933375A CN 2011800281565 A CN2011800281565 A CN 2011800281565A CN 201180028156 A CN201180028156 A CN 201180028156A CN 102933375 A CN102933375 A CN 102933375A
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CN
China
Prior art keywords
fleece
seam
fibroreticulate
melt temperature
fluid
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Pending
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CN2011800281565A
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English (en)
Inventor
U.施奈德
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
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Procter and Gamble Ltd
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Publication date
Application filed by Procter and Gamble Ltd filed Critical Procter and Gamble Ltd
Publication of CN102933375A publication Critical patent/CN102933375A/zh
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    • 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
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    • A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
    • A61F13/15739—Sealing, e.g. involving cutting
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
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    • B29C65/8246—Pressure tests, e.g. hydrostatic pressure tests
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General 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
    • B29C66/71—General 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/70—General 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
    • B29C66/72—General 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
    • B29C66/723—General 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 being multi-layered
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    • B29C66/72343—General 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 being multi-layered comprising a barrier layer for liquids
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General 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
    • B29C66/72—General 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General 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
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    • B29C66/70—General 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
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    • B29C66/90—Measuring or controlling the joining process
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Abstract

本发明公开了包括两种或更多种多孔的、至少部分可熔材料的接缝，所述可熔材料具有基本上相同的熔融温度。用于利用加热的流体制备接缝的方法可用于接合接缝处的所有材料，或者用于仅仅接合接缝中层压体的所选层。

Description

接缝结构及制备接缝的方法
发明领域
本公开涉及接合两种或更多种多孔的至少部分可熔材料的接缝，以及用于制备接合两种或更多种多孔的至少部分可熔材料的接缝的方法。接缝可用作例如套穿一次性吸收制品中的侧缝。
背景技术
具体为一次性尿布的一次性吸收制品被设计成由失禁人群（包括婴儿和病人）穿着。此类尿布围绕穿着者的下体穿着并旨在吸收和容纳尿液及其它身体排泄物，因此防止使用期间接触尿布的制品（例如，衣服、被褥、其他人等）的弄污、润湿或类似污染。一次性尿布可以具有固定侧的套穿尿布（也称作训练裤）的形式获得。固定侧可通过将尿布的前部侧片接合到尿布的后部侧片上来制造。就接合目的而言，侧片的接触表面可至少部分被熔融。熔融外表面可为不可取的，因为熔融的材料有时可与坚硬的粗糙隆起相关联，所述隆起可导致或者被认为导致皮肤刺激或不适。
套穿尿布的固定侧可在使用后（例如，当制品被弄污时）被撕裂以除去产品。因此，期望提供具有相对强的剪切强度和相对弱的剥离强度的接缝，使得侧部能够易于沿着腰部边缘与腿部开口之间的接缝剥离开。如果剪切强度不足，则接缝会在穿着者或看护者打算除去尿布之前由于穿着者活动或流出物载荷而失效。然而，强劲的粘结会具有不可取的美学外观，并且会具有粗糙感。此外，如果剥离强度过度，不向下沿着穿着者腿部整个长度拖拉弄污的套穿尿布会很难除去所述弄污的套穿尿布。如果剥离强度沿着固定侧的长度不一致，则接缝可借助不同的失效模式打开。例如，接缝的一部分可在特定的粘结部位失效，允许接缝开裂。这可为期望的失效模式。然而，固定侧也有可能通过接缝旁边的材料撕裂，或者如果接缝旁边的材料包括一个或多个层压体，则剥离层压体中的一个。这可为非期望的失效模式，因为其可传达固定侧不旨在使用后打开的印象。
仍需要提供相对高的剪切强度和相对低的剥离强度的接缝。仍需要可提供这些竞争特性而不在接缝的外表面上产生粗糙、蓬乱或恶劣感隆起的接缝。
发明内容
接合两个或多个纤维网的方法可包括提供第一纤维网和第二纤维网，所述第一纤维网和第二纤维网中的每一个均为多孔的且具有熔融温度和外表面，第一纤维网和第二纤维网的熔融温度基本上相同；将第一纤维网的至少一部分邻近第二纤维网的至少一部分放置以形成重叠区域；充分加热流体以使得第一纤维网和第二纤维网能够至少部分熔融；将加热流体的喷射流对准第一纤维网的外表面和第二纤维网的外表面中的至少一个；并且允许加热的流体渗透第一纤维网和第二纤维网，使得第一纤维网和第二纤维网中每一个的至少一部分在重叠区域内熔融。第一纤维网与第二纤维网的边缘可被接合以形成重叠接缝或邻接接缝。流体可为环境空气。
所述方法还可包括在重叠区域的至少一部分内压缩第一纤维网和第二纤维网。第一纤维网和第二纤维网可为无纺织物(non-woven)。所述方法还可包括在第一纤维网与第二纤维网之间的接缝内侧位置将第三纤维网粘结到第一纤维网与第二纤维网的至少一个上。第三纤维网如果存在的话可具有与第一纤维网和第二纤维网的熔融温度基本上不相同的熔融温度。第一纤维网与第二纤维网的熔融温度可相同。
所述方法还可包括提供第四纤维网，所述第四纤维网为多孔的且具有熔融温度和外表面，所述第四纤维网的熔融温度与第一纤维网和第二纤维网的熔融温度基本上相同；将第四纤维网的一部分邻近第一纤维网的一部分或第二纤维网的一部分置于重叠区域内；充分加热流体以使得第一纤维网、第二纤维网和第四纤维网能够至少部分熔融；并且允许加热的流体渗透第一纤维网、第二纤维网和第四纤维网，使得第一纤维网、第二纤维网和第四纤维网中每一个的至少一部分在重叠区域内熔融。第四纤维网可与第一纤维网或第二纤维网或第一纤维网与第二纤维网两者重叠。
接缝可根据所述方法制造，并且吸收制品可包括此类接缝。吸收制品中的接缝可具有大于约8:1，或者大于约30:1的剪切载荷与剥离载荷比。
仅仅选择性缝合层压体中所选层的方法可包括提供第一纤维网和第二纤维网，所述第一纤维网和第二纤维网中的每一个均为多孔的且具有熔融温度和外表面，第一纤维网和第二纤维网的熔融温度基本上相同；提供第五纤维网；将第一纤维网的一个边缘邻近第二纤维网的一个边缘放置；将第二纤维网的一个边缘邻近第五纤维网的一个边缘放置，使得第五纤维网不邻近第一纤维网；充分加热流体以使得第一纤维网和第二纤维网能够至少部分熔融；将加热流体的喷射流对准第一纤维网的外表面和第二纤维网的外表面中的至少一个；并且允许加热的流体仅仅渗透第一纤维网和第二纤维网，使得第一纤维网和第二纤维网中每一个的至少一部分熔融。所述方法还可包括将第一纤维网与第二纤维网的熔融部分压缩在一起。第一纤维网和第二纤维网可与第五纤维网压缩在一起。所述方法还可包括提供加强材料，将加强材料的一部分邻近第一纤维网或第二纤维网放置，并且允许加热的流体渗透加强材料。
附图概述
图1A为示例性重叠接缝的示意性侧视图。
图1B为示例性邻接型接缝的示意性侧视图。
图2为根据本公开的接缝的显微照片。
图3为不是根据本公开的方法形成的接缝的显微照片。
图4为用于接合两个或更多个纤维网的旋转装置的简化示意图。
图5为来自图4中旋转装置的示例性滚筒的简化局部剖面图。
图6为用于接合两个或更多个纤维网的固定式设备的透视图。
图7A为被构造为将被穿着的示例性套穿尿布的视图。
图7B为其中面向穿着者的表面朝上的无侧缝示例性套穿尿布的平面图。
图7C为已用剥离力局部分离的示例性侧缝的透视图。
图8为套穿尿布腰部的示意图顶部平面图。
图9为加强接缝的示意性顶部平面图。
图10为加强接缝的示意性顶部平面图。
图11为加强接缝的示意性顶部平面图。
发明详述
如本文所用，术语“接合”描述了其中通过将第一元件直接附加到另一元件上来将所述第一元件直接固定到又一个元件上的构造。
如本文所用，术语“纤维网”是指一种或多种材料的层。术语“层”不必将纤维网局限于单个材料层，并且可包括接合或未接合的相似或不同材料的层压体。
如本文所用，术语“套穿尿布”是指像裤子一样套穿的一般由婴儿和失禁患者穿着的衣服。然而，应当理解本公开也适用于其它吸收制品，例如胶粘尿布、失禁短内裤、女性卫生内衣等，包括旨在由婴儿、儿童和成人使用的吸收制品。
如本文所用，术语“内侧”是指相对于第二元件或材料更靠近制品的横向或纵向中心线的第一元件或材料，第二元件或材料位于第一元件或材料的“外侧”。
如本文所用，术语“多孔的”是指当根据用于如联邦测试方法标准191A的方法5450中所述的Permeability to Air;Cloth;Calibrated Orifice Method的标准测试方法测试时具有至少30cm3/cm2/sec的透气性的材料。附加的测试详细描述于以下测试方法部分中。
如本文所用，术语“至少部分熔融”是指其至少一部分已至少达到至少软化点温度但是未达到熔点温度的材料。“熔融”以其常规意义还指已超过其熔点温度超过材料的至少一部分的材料。
在一些方面，本公开涉及接缝，制备接缝的方法，包括接缝的制品，以及制备包括接缝的制品的方法。如以下更详细所述，接缝可在两个纤维网之间形成，每个纤维网包括一种或多种可熔组件。要缝合的纤维网可邻近彼此定位，并且被加热至至少软化温度或熔融温度，以至少部分熔融所述纤维网的一者或两者。纤维网可在加热后压缩。在本文所述的一些实施方案中，可产生如下接缝：其需要强载荷破坏第一方向上的接缝，以及相对弱的载荷破坏第二方向上的接缝。此类定向强度可用于提供如下接缝：其在使用期间经受第一力或第一组力时为耐用的，在使用期间或使用之后经受第二力或第二组力时为易碎的。以下说明书一般描述了接缝及制备接缝的方法，具体的实施方案，以及与一个或多个具体的实施方案相关联的一些可能的优点。尽管分别描述并示出了多个实施方案，但是要理解的是不同实施方案的多个方面能够被组合以产生另一个实施方案，所述实施方案为简明起见可不明确描述。
要接合的两个纤维网的示意性、不完整的侧正视图示于图1A和1B中。具体地讲，图1A和1B示出了至少两个多孔的纤维网11、12，它们以邻接方式布置以形成接缝10。接缝10包括外表面13、14和纤维网11、12之间的重叠区域15。图1A示出了称作重叠接缝的本文构造，其中两种或更多种材料沿着邻近的重叠表面接合。图1B示出了称作邻接接缝的本文构造，其中两种或更多种材料在其边缘处或靠近边缘接合，并且所述材料远离接缝向后折叠。
纤维网中的至少一个可包括充足的可熔材料以便纤维网易于热接合到另一个纤维网上。纤维网11、12可为多孔的（空气可渗透的、流体可渗透的或蒸气可透过的）并且纤维网11、纤维网12或两者可包括可熔组件。纤维网11、12可为机织织物或无纺织物，并且可包括纤维或聚合物粘合剂，天然纤维如纤维素-木浆、棉、黄麻、大麻；合成纤维如人造丝、聚酯、聚烯烃、丙烯酸类、聚酰胺、芳族聚酰胺、聚四氟乙烯金属、聚酰亚胺；或者粘合剂如双组分纤维、聚酯共聚物、聚氯乙烯、聚醋酸乙烯酯/聚氯乙烯共聚物、共聚物聚酰胺。纤维网可包括材料的共混物，其中一些组分材料不可熔。纤维网11、12可为相同材料或不同材料。纤维网11、12每个均具有熔融温度，并且纤维网11、12的熔融温度可基本上相同。如果熔融温度彼此在30℃内，则它们基本上相同。纤维网11、12的熔融温度可彼此在10℃内，或者彼此在5℃内。在一些实施方案中，纤维网11、12的熔融温度相同。随着纤维网11、12的熔融温度之间的差值减小，控制接缝的能力增强。
缝合方法在其中将形成粘结的区域内及区域周围给予并分散热能。递送以形成粘结的热能越低，所述方法越不太可能损伤附近的材料或冲击邻近预期粘结部位的层。例如，热空气可分散通过多孔层，或者在纤维网11、12的熔融温度不相同处，热空气可用于形成通过外层的孔，允许热空气渗透至一个或多个内部纤维网。在每个纤维网11、12均多孔且纤维网11、12具有基本上相同熔融温度处，能够利用相对低温度、低压力的空气流，导致对粘结区域内或区域周围的纤维极少损伤。该实例在图2中可见，其具有未损伤的纤维84。相比之下，如果纤维网11、12中的一个或居中位于热空气源与纤维网11、12之间的另一个材料层不是多孔的或具有与其它层基本上不相同的熔融温度，则可需要相对高温度、高压力的空气流，其会损伤粘结区域内或区域周围的纤维或膜。该实例在图3中可见，其具有损伤的纤维86。
图4示出了可用于接合纤维网11、12以形成接缝10的设备的简单示意图，所述设备类似于美国专利公开6,248,195中所述的设备，该专利全文以引用方式并入本文。设备20包括具有突出部22的滚筒21；砧滚筒23；用于旋转滚筒21、23的装置24、25；以及包括端值在内的辊26至33，用于引导并推进纤维网11、12通过并远离其中发生能量传递的区域。应当指出的是，不必加热滚筒21和砧滚筒23。此外，设备20包括机架（未示出）；通向突出部22的流体喷嘴（未示出）；用于加热流体的温度控制装置（未示出）；用于调节流体压力的压力装置（未示出）；以及用于驱动辊26至33的装置（未示出），用于使纤维网11、12可控制地向前通过其中发生能量传递的区域，并且用于使得所得接缝10向前至诸如单垫处理设备的下游设备，该设备收拢在尿布的固定侧。
为清楚起见，纤维网11、12的上游端或来源及接缝10的下游目的地或使用者均未示出。纤维网可以卷筒形式产生，并且可提供上游退绕和接头装置以使得此类纤维网的向前连续长度通过接合装置和/或变换器以制备纤维网结构。为简化起见，设备20在本文被描述为包括滚筒21和砧滚筒23。不旨在以任何方式将所述方法限制为包括滚筒的设备。
图5示出了具有代表性突出部22的滚筒21的简化局部剖面图。滚筒21可包括例如圆锥形或圆柱形区域34，需要至少部分熔融纤维网11、12的可熔组件的流体被引导通过该区域。为简单起见，以下讨论是指如图5所示的圆柱形区域34，然而，圆锥形、箱形、棱锥形或其它形状也能够用于区域34。将流体喷嘴（未示出）连接到圆柱形区域34的顶面35上。流体可为环境空气或其它气体。此外，可利用能量场实现部分熔融效应。流体可被加热至由纤维网11、12的较低熔点减去30℃至纤维网11、12的较低熔点加上100℃范围内的温度。流体压力可在0.1×105牛顿/平方米至1×106牛顿/平方米的范围内。圆柱形区域34的顶面35处的直径在1毫米至8毫米的范围内且圆柱形区域34的孔口36的直径可在0.1毫米至6毫米的范围内。圆柱形区域34可以与纤维网11、12的重叠区域15相同或几乎相同的速度移动10至1000毫秒范围内的时间间隔。这使得加热的流体能够流向至少一个外表面13、14以实现依据强度和柔软性的优质接缝。当然，可利用较短或较长的持续时间，其中较低的强度或柔软性分别可接受。滚筒21上的突出部22可以预定图案被设置，其中每个突出部被构造并设置以促成纤维网11、12中的重叠区域15被接合以实现接缝10中重叠区域15的预定图案。滚筒21可具有突出部22的锯齿形图案，所述突出部围绕滚筒21的每个端部周向延伸。
砧滚筒23可为平滑表面的钢制直圆柱体，其能够由调速的直流马达独立地动力旋转。在可供选择的构造中，砧滚筒23可用与纤维网11、12相同的速度在重叠区域15处移动20至1000毫秒范围内的时间。在该时间间隔期间，重叠区域15变形，接合发生且随后冷却。也可具有多个以产品节距的0.5和1.5倍之间的节距范围安装在载体上的砧和流体喷嘴。
提供装置24、25以驱动滚筒21和砧滚筒23。在传动滚筒21与砧滚筒23的表面速度之间可具有预定但可调节的关系。其可为同步或异步的，即具有相等的表面速度或者具有预定的表面速度差，其中滚筒21或砧滚筒23比另一个传动更快。包括端值在内的辊26至33按如下表面速度受到驱动，所述表面速度保持预定的张力或拉伸水平以便没有松弛的纤维网状况或过度张紧的/拉伸的纤维网促成不可取的后果。示出了八个辊26至33，然而，应当理解可利用更多或更少的辊。在一些实施方案中，可不需要辊，因为纤维网11、12以及接合的纤维网可通过合并到传动滚筒21和砧滚筒23中的元件驱动或者通过设备20上游或下游的其它功能设备驱动。
图6示出了等同的固定式方法。与图4中的设备形成对比，图6中的设备在接缝形成期间不转动。固定式设备可被固定，其中纤维网11、12移动到设备上，或者一个或多个组件可被设计成在纤维网沿着生产线传送时与纤维网11、12移动某一距离。图6中的示例性设备为具有风口36和压缩板80的集成组合件82。换热器（未示出）合并到组合件82中。压缩板80与第二平板（未示出）啮合，所述第二平板也可具有突出部22，或者可为平滑表面。当然能够利用单独的风口和压缩板。缝合操作可在一体式折叠密封单元中实现，如授予Schmitz的美国专利公开5,779,831中所述。
以邻近方式排列以形成如图1A或1B所示的接缝10的至少两个纤维网11、12的接合可包括提供第一纤维网11和第二纤维网12，第一纤维网11和第二纤维网12中的每一个均为多孔的且具有熔融温度和外表面13、14，第一纤维网11和第二纤维网12的熔融温度基本上相同。所述方法还可包括将第一纤维网11的至少一部分邻近第二纤维网12的至少一部分放置以形成重叠区域15。流体可被充分加热以使得第一纤维网和第二纤维网11、12能够至少部分熔融。加热流体的喷射流可对准第一纤维网11的外表面13和第二纤维网12的外表面14中的至少一个。可允许流体渗透第一纤维网11和第二纤维网12，使得第一纤维网11和第二纤维网12中每一个的至少一部分在重叠区域15中熔融。加热的流体在受控的温度和压力下可由流体喷嘴进入突出部22的圆柱形区域34内并通过孔口36离开，导致受控且浓缩的加热流体喷射流的形成，所述喷射流被引向要接合的纤维网11、12的外表面13、14。
所谓受控是指一旦选择标称设定点，则温度和压力维持在指定的范围内。例如，设定点可由上述范围选择，随后温度可维持在标称设定点附近的固定范围内，例如±30℃，并且压力可维持在标称设定点附近的固定范围内，例如±1巴。可接受的范围将取决于要接合的材料特性与所选择的标称设定点之间的关系，所述特性例如软化点和/或熔融温度。例如，高于要接合的一种或多种材料的熔融温度的标称设定点可需要比低于要接合的一种或多种材料的熔融温度的标称设定点更苛刻的控制范围。控制范围可关于标称设定点不对称。所谓充分加热是指流体被加热至将使得一个或多个纤维网能够至少部分熔融或至少软化的温度。充分加热可随所用材料和设备而改变。例如，如果加热的流体几乎立刻施用到一个或多个纤维网上而很少或没有时间冷却，则流体可被加热至所述一个或多个纤维网的大约软化点或大约熔点。如果加热的流体经过某一时间或距离间隔引向一个或多个纤维网，使得加热的流体可在与所述一个或多个纤维网作用稍前冷却，可有必要将流体加热至所述一个或多个纤维网的软化点或熔点以上，也许明显在软化点或熔点之上。
流体也可用脉冲施用递送到外表面13、14上。可调节加热的流体的喷射冲击，使得由喷射引入的能量加上由其它装置如加热的砧（如果砧被加热）、喷嘴表面引入的能量、纤维网11、12的变形以及纤维网11、12的内摩擦足以至少部分熔融纤维网11、12中的可熔组件以产生一定厚度，所述厚度将在压缩时于重叠区域15处形成强接合。可熔组分的熔融可遍及纤维网11、12以非均匀方式发生。
本文所述过程中的能量传递的短持续时间可为动态过程，并且可横跨可熔组件的横截面产生温度梯度。换句话讲，可熔组件的芯可保持为固体而可熔组件的外表面熔融或接近熔融。即使低于熔融温度，外表面仍可达到软化点，使得材料的塑性变形可在比环境温度下相同材料低得多的载荷下发生。因此，如果接缝10中要接合的一种或多种材料具有软化点，则可调节所述过程以实现纤维网11、12的至少一部分中的温度介于软化点与熔点之间。在一个或多个可熔组件的软化点或高于所述软化点但低于熔点的温度的利用可允许在纤维网11、12之间产生强粘结而对可熔组件的结构破坏降低，例如衰减或换句话讲削弱可熔组件。
所述方法还可包括在可熔组件至少部分熔融（即，处于发粘状态）时用压缩工具压缩接缝10的步骤。这能够通过利用压缩工具向接缝10施加压力实现。压缩工具的温度可至少低于接缝10的熔点。可熔组件的粘着性容许纤维网11、12的接合，因此熔融的纤维网材料的积聚可被减少或避免。此类熔融的材料在固化时于接缝10的外表面上形成坚硬的粗糙隆起。压缩工具可根据审美标准设计成例如在纤维网11、12被接合的位置提供离散的成型点。离散的压缩点还可使得接缝较容易打开。离散的压缩点的图案与间距可改变。一般来讲，离散的压缩点的图案与间距的微小差别不改变打开接缝所需的总体的力。然而，离散的压缩点之间的距离可影响对打开接缝所需的力的感知。具体地讲，离散的压缩点之间的大距离可导致接缝层的突变、不连续分开的感觉，而离散的压缩点之间的较小距离可导致接缝层的平滑、连续分开的感觉。压缩点一般将呈现压缩板80上突出部22的形状和间隔。突出部22可为大致椭圆形，如图6所示，或者可具有与期望的移除力和移除力感知一致的任何其它几何形状或装饰形状。突出部22可规则或不规则间隔，并且可以多个方向取向，如图6的示例性图案所示。
在一些实施方案中，如本文所述的方法为用于制备吸收制品的方法的一部分。例如，用于制备吸收制品的方法可包括提供第一纤维网11和第二纤维网12，第一纤维网11和第二纤维网12中的每一个均为多孔的并具有熔融温度和外表面13、14，第一纤维网11和第二纤维网12的熔融温度基本上相同。第一纤维网11的至少一部分可邻近第二纤维网12的至少一部分放置以形成重叠区域15。流体可被充分加热以使得第一纤维网和第二纤维网11、12能够至少部分熔融。加热流体的喷射流可对准第一纤维网11的外表面13和第二纤维网12的外表面14中的至少一个。可允许流体渗透第一纤维网11和第二纤维网12，使得第一纤维网11和第二纤维网12中每一个的至少一部分在重叠区域15中熔融。第一纤维网11和第二纤维网12可包括侧片、前部、后部或它们的组合。吸收制品可为套穿尿布。套穿尿布可旨在用于婴儿、儿童、成人或家庭宠物。第一纤维网和第二纤维网可为无纺材料。第一纤维网和第二纤维网还可包括弹性膜。重叠区域15可不包括第一纤维网、第二纤维网或两者的弹性膜。用于制备吸收制品的方法还可包括压缩重叠区域15。重叠区域15的压缩与重叠区域15中纤维网11和12的部分熔融可同时进行或几乎同时进行。例如，重叠区域15的压缩可在纤维网11和/或12部分熔融的5毫秒、或10毫秒、或50毫秒内发生。通过该方法形成的吸收制品可具有5:1、或10:1、或20:1、或30:1的剪切强度与剥离强度比。
纤维网11、12可为具有30至500克/平方米范围内的基重的无纺纤维网，包含由小于一丹尼尔的微纤维至1至7丹尼尔范围的常规纤维的范围内的纤维。无纺纤维网也可包含具有股线的稀松布材料，所述股线具有大于1毫米的直径。部分基于纤维网的厚度，用该方法接合纤维网11、12所需的时间间隔可在10至1000毫秒的范围内。在一些实施方案中，30至250毫秒可用于加热且5至250毫秒可用于压缩/冷却。在一些实施方案中，压缩步骤可相当短，几乎为瞬间。所用时间间隔可随标称压力和温度选择改变。在较低的压力和/或温度下无损伤的材料可容忍较高的加工时间，而较高的压力和/或温度可用于较短的加工时间。
已描述了利用加热的流体接合至少部分熔融的材料。然而，基于接缝中的层的熔融温度制造很小区别或无区别。如果一个或多个层具有与另外一层或多个层显著不同的熔融温度，则空气温度或材料暴露于加热空气的时间长度或两者均被调节以调和接缝中最高的熔融温度。已发现，通过选择类似熔融温度的接缝材料，有可能增加剪切载荷与剥离载荷的比率从大约5:1至30:1或更高。此外，类似熔融温度的纤维网之间的接缝可提供更一致的粘结。因此，当接缝被剥离时，失效模式可为一致的，沿着接缝长度在粘结部位打开。一致的打开模式可在打开接缝后提供整洁、干净的边缘。相比之下，如果“接缝”不是通过破坏接缝打开，而是通过撕裂或分层邻接接缝的纤维网材料，则不规则边缘可存在。
利用类似熔融温度的纤维网也可提供加工有益效果。当调节工艺参数用于较高熔融温度时，具有较低熔融温度的接缝中的纤维网会在加工期间受损。为了限制该损伤，较小孔口可用于将热空气流禁闭于限制区域。利用相对于接缝中纤维网的熔融温度更适中的温度和保压时间有可能利用较大的孔口。较大的孔口会不太易于使工具污染，因此需要较低频率或较小强度的清洁和维护。此外，有可能减少接缝材料暴露于热空气的保压时间，导致更快速的加工。
此外，利用较大的孔口（以及相关的较低空气压力）可使得能够利用该方法有选择地粘结层压体的独立层。例如，有可能粘结两个无纺层而无需粘结下方的膜，即使所述膜具有比粘结的无纺层更低的熔融温度。不受理论的束缚，较低的气压可限制加热空气对下层的影响。当然，能够通过改进工艺参数或材料特性将更多的层添加到所述粘结，改变所述工艺参数例如，通过增加空气温度、空气压力、和/或空气循环时间，所述材料特性例如基重、孔隙率、软化温度或熔融温度。层的选择性粘结参照示例性吸收制品的以下描述在以下更详细地讨论。
上述方法可用于一次性吸收制品的制造。具体地讲，所述方法可用于制备用于一次性套穿尿布或套穿内衣的侧缝，包括失禁制品和妇女卫生产品。如图7A和7B所示的示例性吸收制品40可具有外表面42、内表面44、前部46、后部48、裆部50，所述前部和所述后部中的每一个均具有侧片52，所述侧片52具有侧边54和将前部和后部的侧片接合在一起以形成腿部开口58和腰部开口60的侧缝56。吸收制品40可包括基础结构层；定位于前部的每个侧片中的可弹性延展的拉伸层压体，前部拉伸层压体；定位于后部的每个侧片中的可弹性延展的拉伸层压体，后部拉伸层压体；以及至少一个定位于前部、后部或前部与后部两者中的弹性化腰带。吸收制品40包括腿部开口58，其可另外包括弹性腿部部件以改善裆部50中腿部处的贴合性。
吸收制品40可具有包括主片和一对侧翼片的裆部50。吸收芯可定位于裆部的主片内，因为身体流出物可在该区域内排放。吸收制品40的外表面42包括当在使用期间如预期贴合穿着者时远离穿着者的身体、靠近穿着者的衣服（如果存在的话）定位的那部分。吸收制品40的内表面44与外表面42相对并包括当在使用期间如预期贴合穿着者时邻近穿着者的身体定位的吸收制品40的那部分。
可弹性延展的拉伸层压体（前拉伸层压体和后拉伸层压体）可在前部46、后部48或前部46与后部48两者中的每个侧片52中形成。每个拉伸层压体可被机械拉伸或牵拉以允许拉伸层压体在至少横向上可弹性延展。横向（x方向或宽度）被定义为平行于吸收制品40的横向中心线62的方向；相比之下，纵向（y方向或长度）为垂直于吸收制品40的横向中心线62的方向。侧片52可为其它元件的延伸，所述其它元件例如顶片、底片或其它元件，或者侧片52可为接合到其它元件上的离散纤维网，所述其它元件例如顶片或底片或两者。在侧缝56中，拉伸层压体可通过机械拉伸活化以提供该区域中的附加延展性。侧缝56也可不通过机械拉伸活化。
为了提供吸收性和贴合性以包含身体排泄物，吸收制品40可包括本领域已知的多种结构中的任何一种，包括但不限于顶片、吸收芯、底片、流体采集层、阻挡层或阻挡箍、腿弹性部件、衬圈箍、锚定带、扣紧系统、气味控制体系、入厕训练助件等。一些合适的结构和材料公开于例如以下专利中：US3,860,003；US4,909,803；US4,695,278；US4,795,454；5,360,420；US4,610,478；US7,074,215；US7,179,951；US7,381,202；US7,666,175；和US7,699,825。
用于一次性套穿尿布的接缝可通过将前部的侧片接合到后部的侧片上形成。在一些实施方案中，一次性套穿尿布包括前部46的侧片52和后部48的侧片52。侧片52可被接合以形成重叠或邻接型侧缝，即根据上述方法的接缝10。在一些实施方案中，可利用单独的单一侧片，其被缝合到前部46和后部48，或者其与前部46或后部48连续并缝合至相对部分。当然，本文所述的接缝及制备接缝的方法可用于其中期望相对高的剪切载荷和相对低的剥离载荷的任何应用中。例如，本文所述的接缝及制备接缝的方法可用于形成低剥离载荷的接缝，以保持吸收制品处于关闭位置用于单个单位的销售，如2009年11月24日提交的题目为“Absorbent Articles and Method forManufacturing Same”的美国专利申请12/624,822中所述。在不同的应用中，用于制备接缝的方法可根据需要改变以产生打开接缝需要或多或少的力的接缝。
剪切强度可相当于对在由线92、94限定的平面内施加的力的接缝强度。在吸收制品情况下，这一般将对应沿着穿着者腰部周围施加的力，例如活动产生的力，包括久坐行为期间躯干的活动如呼吸和更剧烈行为期间的躯干活动，例如滚动、爬行、端坐、行走等。剥离强度可相当于对垂直于由线92、94限定的平面施加的力的接缝强度。在吸收制品情况下，这一般将对应有意剥离接缝15中的层所施加的力，如当由穿着者身上除去吸收制品时，或者破坏接缝以检查弄污情况或调节吸收制品的贴合性时。应当理解接缝的定向强度并不取决于其中该接缝形成的取向，并且在可供选择的取向中产生的制品将预期具有与在指明取向中形成的制品类似的特性。换句话讲，无论剪切力在由线92、94限定的平面内是在沿着线92还是沿着线94的方向上施加，剪切强度应为强的。
提供在一个方向上难以破坏而在另一方向上易于破坏的接缝允许诸如一次性尿布的制品被构造成在使用期间较强但是易于除去。例如，如上所述，如本文所述的接缝可用于接合吸收制品的侧片，以形成例如套穿尿布。接合侧片的接缝相对于剪切负载应为强的。否则的话，侧缝可在正常活动期间无意和/或不可取地被破坏，导致尿布松垮或尿布脱落。还可期望接合侧片的接缝易于用剥离载荷破坏，以便能够无需向下沿着穿着者腿部的整个长度拖拉弄污的尿布而将尿布除去。由于诸如呼吸、坐立和行走的正常活动一般不产生高的剥离载荷，因此较低的剥离载荷可有利于吸收制品的移除而不会显著增加使用期间无意的和/或不可取的接缝失效的风险。
在一些实施方案中，一个或多个侧片可包括弹性膜。弹性膜可向一个或多个侧片提供弹性返回力，使得对于一定范围的穿着者尺寸和形状，侧片均有助于保持吸收制品靠着穿着者的身体。在一些实施方案中，弹性膜不延伸至包括在接缝15中的一个或多个侧片的边缘。例如，弹性膜可为图10中的像层88那样的层，其为一个或多个侧片的一部分，但并非接缝的一部分。在该方式中，不具有与侧片层压体中其它层的熔融温度基本上相同的熔融温度的弹性膜能够被用于如本文所述的接缝。作为另外一种选择，侧片可仅仅包括具有基本上相同熔融温度的层，所述层含有或不含弹性组件。
如上所述，通过控制工艺因素有可能仅仅接合多层复合材料中所选择的层，所述工艺因素例如流体温度、流体压力、流体喷嘴几何形状、流体喷嘴与材料之间的距离、以及流体循环时间。例如，如图8所示，有可能仅仅接合吸收制品侧面的耳片材料，无需也捕获吸收芯70和/或腿箍68材料的邻近部分。这可为有用的，因为将所有这些层接合在一起为不可取的，并且一旦层邻近彼此放置则以任何其它方式仅仅接合所选择的层会变得困难或不可能。例如，腿箍68可旨在远离下面的结构“直立”以在穿着者的腿部提供对液体渗漏的阻挡。如果腿箍被固定到下层上，则其或许不能够“直立”，并且阻挡功能会受影响。传统的加热辊隙接头不能够选择性地接合层压体的仅仅某些层。类似地，当接合多孔的较低基重的材料时，胶水及其它粘合剂可有意无意地渗透材料并接合其它层。
利用本文所述的方法，有可能在正面接缝76和背面接缝78处形成不同的接缝。如图8所示，背面侧缝78包括与侧片52相关联的两层无纺材料64、底片的无纺层64、底片的聚合物膜层74、以及腿箍68的一部分。正面侧缝76可仅仅包括与侧片52和底片相关联的非织造材料64。换句话讲，正面侧缝76可不渗透通过聚合物膜层74。因此，在该示例性实施方案中，正面侧缝76在吸收制品40的前面提供易于打开的粘结，而背面侧缝78提供高强度的粘结，其粘结来自吸收制品40中多个结构的层。在此类实施方案中，背面侧缝78可利用任何接合技术形成，包括本文所述的方法。
接缝能够利用附加材料加强而无需利用图9-11所示的示例性结构捕获下方的层，所述图示出了紧邻接缝10但并非接缝10的一部分的层88。例如，在图9中，一个纤维网11已包裹在另一个纤维网12周围，提供6层结构，所述结构可在接缝处提供相对于图1A所示的非包裹结构附加的堆积体积和强度。图10示出了两个纤维网11、12中的每一个在缝合之前折叠，产生一个8-层结构。也有可能提供如图11所示的专用加强材料90。专用加强材料90的使用可有助于形成较强的接缝而不会增加与如图10所示的8-层结构一样多的堆积体积。为了保持接缝的易于打开有益效果，图11中的专用加强材料可为多孔的并且可具有与接缝中的其它材料基本上相同的熔融温度。当然，也有可能通过包括附加的邻近层来加强接缝，所述层具有不同于加强接缝的功能，例如，在接缝中延伸并包括层88。可能期望利用可供选择的加强结构，其中例如，层88不是多孔的，或者具有基本上不同于纤维网11或纤维网12的熔融温度的熔融温度。
其中如本文所述的接缝可有用的其它实例包括一次性或轻型衣服，例如病号服、连衣工作服、围裙、围兜等。尽管如上所述的接缝不必为可重复扣紧的，但是接缝可与可重复扣紧的扣紧系统联合使用，所述可重复扣紧的扣紧系统例如机械扣件、粘合剂扣件、胶粘剂扣件等，使得纤维网能够在接缝开裂后重新接合。例如，当检查看套穿尿布是否被弄污时，或者用于调节包括一次性衣服的一次性制品的贴合性时，这可为有用的。
实施例
下表示出了热空气接缝中的纤维网材料适应类似熔融温度材料的效果。
*NW1为由BBA以商品HEC加工的27gsm的梳理无纺织物。
**膜为嵌段共聚物（热塑性弹性体）。
+对应于穿着/使用期间的重叠接缝。
++对应于穿着/使用期间的邻接接缝。
+++对应于移除/接缝撕裂。
实施例1代表包括具有显著不同熔融温度的纤维网的接缝。实施例2-4代表具有基本上相同熔融温度的纤维网在不同加工温度下的热空气缝合方法。如能够由表中看出的，除去接缝中的高熔融温度纤维网允许在较低温度、压力和加工时间下形成较大横向剪切力的接缝。较低温度也可产生较高的横向剪切载荷与纵向剥离载荷比和/或样本之间的较低差异。根据实施例2-4的接缝未表现出过度粘结或粗糙。每个实施例的样本尺寸为10。使用Instron试验机进行测量。在该实施例中，横向（CD）对应于图7C中的线92，而纵向（MD）对应于图7C中的线94。
透气性的测试方法
根据联邦测试方法标准191A中的方法5450利用Testex FX3300仪器（或等同物）测量透气性，使用38cm2的样本面积和横跨样本的125Pa的压降。所用样本尺寸可以不总是7英寸乘7英寸（大约17.8cm乘17.8cm），然而，样本尺寸总应足以用于38cm2的圆形面积以便不会以任何方式影响测试结果。低于Testex FX3300仪器手册列出为0.05cm3/cm2/sec的仪器范围下限的样本测试出于本公开的目的而言被认为是不可渗透的。
本文所公开的量纲和值不旨在被理解为严格地限于所述的精确值。相反，除非另外指明，每个这样的量纲均旨在表示所述值以及围绕该值功能上等同的范围。例如，所公开的尺寸“40mm”旨在表示“约40mm”。
除非明确地不包括在内或换句话讲限制，本文所引用的每篇文献，包括任何交叉引用的或相关的专利或专利申请，均特此以引用方式全文并入本文。任何文献的引用不是对其作为本文所公开的或受权利要求书保护的任何发明的现有技术，或者其单独地或者与任何其它参考文献的任何组合，或者参考、提出、建议或公开任何此类发明的认可。此外，当本发明中术语的任何含义或定义与以引用方式并入的文件中术语的任何含义或定义矛盾时，应当服从在本发明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，在不背离本发明的精神和范围的情况下可作出许多其它的更改和修改。因此，随附权利要求书中旨在涵盖本发明范围内的所有这些改变和变型。

Claims (15)

1.一种接合两个或更多个纤维网的方法，所述方法包括：
提供第一纤维网和第二纤维网，所述第一纤维网和第二纤维网中的每一个均为多孔的且具有熔融温度和外表面，所述第一纤维网和第二纤维网的熔融温度基本上相同；
将所述第一纤维网的至少一部分邻近所述第二纤维网的至少一部分放置以形成重叠区域；
充分加热流体以使得所述第一纤维网和第二纤维网能够至少部分熔融；
将所述加热流体的喷射流对准所述第一纤维网的外表面和所述第二纤维网的外表面中的至少一个；以及
允许所述加热的流体渗透所述第一纤维网和第二纤维网，使得所述第一纤维网和第二纤维网中每一个的至少一部分在所述重叠区域内熔融。
2.如权利要求1所述的方法，其中所述第一纤维网和第二纤维网的形成所述重叠区域的部分被接合以形成重叠接缝。
3.如权利要求1所述的方法，其中所述第一纤维网和第二纤维网的形成所述重叠区域的部分被接合以形成邻接接缝。
4.如前述权利要求中任一项所述的方法，其中所述流体为环境空气。
5.如前述权利要求中任一项所述的方法，所述方法还包括在所述重叠区域的至少一部分中压缩所述第一纤维网和第二纤维网。
6.如前述权利要求中任一项所述的方法，其中所述第一纤维网和第二纤维网为无纺织物。
7.如前述权利要求中任一项所述的方法，所述方法还包括在所述第一纤维网与所述第二纤维网之间的接缝内侧位置将第三纤维网粘结到所述第一纤维网与所述第二纤维网的至少一个。
8.如权利要求7所述的方法，其中所述第三纤维网具有与所述第一纤维网和第二纤维网的熔融温度基本上不同的熔融温度。
9.如前述权利要求中任一项所述的方法，其中所述第一纤维网和第二纤维网的熔融温度是相同的。
10.如权利要求7、8或9中任一项所述的方法，所述方法还包括提供第四纤维网，所述第四纤维网为多孔的且具有熔融温度和外表面，所述第四纤维网的熔融温度与所述第一纤维网和第二纤维网的熔融温度基本上相同；
将所述第四纤维网的一部分邻近所述第一纤维网的一部分或所述第二纤维网的一部分放置于所述重叠区域内；
充分加热流体以使得所述第一纤维网、第二纤维网和第四纤维网能够至少部分熔融；以及
允许所述加热的流体渗透所述第一纤维网、第二纤维网和第四纤维网，使得所述第一纤维网、第二纤维网和第四纤维网中每一个的至少一部分在所述重叠区域内熔融。
11.如权利要求10所述的方法，其中所述第四纤维网与所述第一纤维网或所述第二纤维网重叠。
12.如权利要求11所述的方法，其中所述第四纤维网与所述第一纤维网和所述第二纤维网重叠。
13.一种接缝，所述接缝根据前述权利要求中任一项所述的方法生产。
14.一种吸收制品，所述吸收制品包括如权利要求13所述的接缝。
15.如权利要求14所述的吸收制品，其中所述剪切载荷与剥离载荷的比率大于约8:1。
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