CN104797225A - 用于粘结基底的设备和方法 - Google Patents

用于粘结基底的设备和方法 Download PDF

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Publication number
CN104797225A
CN104797225A CN201380055520.6A CN201380055520A CN104797225A CN 104797225 A CN104797225 A CN 104797225A CN 201380055520 A CN201380055520 A CN 201380055520A CN 104797225 A CN104797225 A CN 104797225A
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CN
China
Prior art keywords
basal layer
rotating cylinder
anvil roller
peripheral surface
external peripheral
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.)
Granted
Application number
CN201380055520.6A
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English (en)
Other versions
CN104797225B (zh
Inventor
D·C·欧德维
J·M·弗兰克
G·X·黄
U·施奈德
M·D·龙
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
Priority to CN201810113491.9A priority Critical patent/CN108186202A/zh
Publication of CN104797225A publication Critical patent/CN104797225A/zh
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Publication of CN104797225B publication Critical patent/CN104797225B/zh
Expired - Fee Related legal-status Critical Current
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
    • A61F13/15739—Sealing, e.g. involving cutting
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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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • 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
    • B29C66/01—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
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
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    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • 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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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81457—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a block or layer of deformable material, e.g. sponge, foam, rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
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    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
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Abstract

本发明公开了一种方法，其包括围绕轴线旋转转筒以及围绕轴线邻近转筒旋转砧辊，以便在该砧辊和该转筒之间形成辊隙。转筒包括流体喷嘴和压制构件，压制构件具有外表面。砧辊包括柔顺外圆周表面。第一基底和第二基底在纵向上被推进到转筒上。流体喷嘴径向向外移动，并且受热流体的射流被引导到基底上。流体喷嘴径向向内回缩，并且压制构件被径向向外移位。基底被推进穿过辊隙并在压制构件和砧辊之间被压缩，使得压制构件使砧辊的柔顺外圆周表面变形。

Description

用于粘结基底的设备和方法
技术领域
本公开涉及用于制造吸收制品的方法，并且更具体地，涉及用于在吸收制品的制造期间将基底粘结在一起的设备和方法。
背景技术
沿着装配线，可通过将部件添加到推进的连续材料纤维网和/或以其它方式修改推进的连续材料纤维网来装配各种类型的制品，诸如尿布和其它吸收制品。在一些方法中，推进的材料纤维网与其它推进的材料纤维网组合。在其它方法中，从推进的材料纤维网产生的单个部件与推进的材料纤维网组合，然后所述推进的材料纤维网继而与其它推进的材料纤维网组合。在一些情况下，从推进的一个或多个纤维网形成的单个部件与从其他推进的一个或多个纤维网形成的其他单个部件组合。用来制造尿布的材料纤维网和组成部件可包括：底片、顶片、腿箍、腰带、吸收芯部件、前耳片和/或后耳片、扣紧部件、以及各种类型的弹性幅材和部件诸如腿弹性部件、阻隔腿箍弹性部件、拉伸侧片和腰弹性部件。一旦组装好了所期望的组成部件，使推进的纤维网和组成部件经受最终刀切以将该纤维网分离成离散的尿布或其它吸收制品。
在一些转换加工构型中，彼此间隔开的离散的基础结构在纵向上被推进并且被布置成具有平行于横向的纵向轴线。然后将离散的基础结构的相对的腰区与在纵向上推进的连续长度的可弹性延伸的前带纤维网和后带纤维网连接。虽然是连接至基础结构，但前带纤维网和后带纤维网沿纵向保持在完全拉伸状态，从而形成连续长度的吸收制品。然后可在横向上折叠所述连续长度的吸收制品。在折叠过程期间，在一些转换加工构型中，前带纤维网和后带纤维网中的一者被折叠成与相对的带成面对关系。然后前带和后带可被粘结在一起以在尿布上产生侧缝。
前带的部分和后带的部分可被部分地熔融并压缩在一起以产生侧缝。缝接方法可包括推进前带和后带穿过形成于旋转的砧辊和旋转的压缩工具之间的辊隙。当前带和后带推进穿过辊隙时，压缩工具可抵靠砧辊压缩前带和后带。砧座和压缩工具可由刚性材料制成。在一些方法中，前带和后带被压缩的时间量可影响接缝的强度和品质。具体地，增加的压缩时间可提高接缝的品质和强度。然而，在利用刚性砧辊和刚性压缩工具的高速制造过程中，砧辊和压缩工具可被间隔开以便防止砧辊和压缩工具之间的干涉作用。因此，当前带和后带穿过形成于砧辊和压缩工具之间的辊隙时，压缩时间可几乎为瞬时的。
在一些方法中，在非切向于压缩工具的外表面和砧辊的外圆周表面的方向上压缩推进的基底可改善接缝的品质和强度。然而，在利用间隔开的刚性压缩工具和刚性砧辊以便防止干涉作用的方法中，基底可在切向于砧辊的外表面和压缩工具的外表面的方向上被压缩。
因此，有益的是提供用于在高速制造过程中增加用于将基底粘结在一起以形成侧缝的压缩时间的设备和方法。此外，还有益的是提供一种用于在非切向于压缩工具的外表面和砧座的外圆周表面的方向上压缩基底的方法和设备。
发明内容
本公开的多方面包括一种方法，该方法包括以下步骤：围绕旋转轴线旋转转筒，转筒包括流体喷嘴和压制构件，压制构件具有外表面；围绕旋转轴线邻近转筒旋转砧辊，砧辊具有柔顺外圆周表面，砧辊和转筒在它们之间形成辊隙；在纵向上将第一基底层推进到转筒上，第一基底层具有内表面和外表面，其中第一基底层的外表面邻近转筒；在纵向上推进第二基底层，第二基底层具有内表面和外表面，其中第一基底层位于第二基底层和转筒之间，其中第一基底层和第二基底层具有合并的未压缩厚度；围绕转筒的一部分包裹第一基底层和第二基底层；将流体加热至足以至少部分地熔融第一基底层和第二基底层的温度；相对于转筒的旋转轴线径向向外移动流体喷嘴；将受热流体的射流引导到第一基底层和第二基底层上；部分地熔融第一基底层和第二基底层；相对于转筒的旋转轴线径向向内回缩流体喷嘴；相对于转筒的旋转轴线径向向外移位压制构件；推进第一基底层和第二基底层穿过辊隙；以及在压制构件和砧辊之间压缩第一基底层和第二基底层并使砧辊的柔顺外圆周表面变形。
本公开的多方面包括一种用于将第一基底和第二基底粘结在一起的设备，其中第一基底和第二基底具有合并的未压缩厚度。该设备包括转筒，所述转筒包括外圆周表面和位于外圆周表面中的转筒孔，其中转筒适于围绕旋转轴线旋转。该设备包括可移动地连接至转筒的流体喷嘴，所述流体喷嘴相对于所述转筒孔径向向内定位并适于径向向外引导流体穿过转筒孔。该设备包括砧辊，所述砧辊包括邻近转筒定位的外圆周表面以便限定砧辊和转筒之间的辊隙。砧辊适于围绕旋转轴线旋转并包括限定砧辊的外圆周表面的柔顺套筒。砧辊的外圆周表面可朝砧辊的旋转轴线变形。该设备包括可移动地连接至转筒的压制构件，所述压制构件相对于所述转筒孔径向向内定位并适于延伸穿过转筒孔。
附图说明
图1为尿布裤的透视图。
图2A为图1所示尿布裤在部分切除之后的平面图。
图2B为尿布裤的第二构型在部分切除之后的平面图。
图3A为沿线3A-3A截取的图2A和2B的尿布裤的剖视图。
图3B为沿线3B-3B截取的图2A和2B的尿布裤的剖视图。
图4为适于制造预扣紧的裤型尿布的转换加工设备的示意性侧视图。
图5A为沿线A-A截取的出自图4的连续长度的基础结构组件的视图。
图5B1为沿线B1-B1截取的出自图4的离散的基础结构的视图。
图5B2为沿线B2-B2截取的出自图4离散的基础结构的视图。
图5C为沿线C-C截取的出自图4的连续长度的推进的前侧片材料和后侧片材料的视图。
图5D为沿线D-D截取的沿纵向MD彼此间隔开的且由出自图4的前侧片材料和后侧片材料彼此连接的多个离散的基础结构的视图。
图5E为沿线E-E截取的折叠的多个离散的基础结构的视图，所述基础结构具有呈面对关系的出自图4的前侧片材料和后侧片材料。
图5F为沿线F-F截取的在纵向MD上推进的出自图4的两个离散的吸收制品的视图。
图5G为沿线5G-5G截取的出自图5D的第一基底和第二基底的重叠区域的视图。
图6A为适于缝接预扣紧的裤型尿布的粘结机设备的示意性侧视图。
图6A1为图6A的粘结机设备的详细的示意性侧视图。
图6B为图6A的接缝机工位的正视图。
图6B1为图6B的接缝机工位的详细正视图。
图7为缝接工位的详细分解图。
图8为缝接工位的正视图。
图9为被构造成使第一基底层和第二基底层在z方向上变形的压制构件和砧辊的局部侧正视图。
图10为处于第一构型的缝接工位的透视图。
图11为适于接缝预扣紧的尿布的粘结机设备的示意性侧视图。
图12为处于第二构型的缝接工位的透视图。
图13为压制构件和砧辊的局部侧正视图。
图14为压制构件和砧辊的局部侧正视图。
图15为压制构件和砧辊的局部侧正视图。
图16-19为适于接缝预扣紧的裤型尿布的粘结机设备的透视侧视图。
具体实施方式
本申请要求2012年10月23日提交的美国临时申请序列号61/717,268的权益，其全部内容以引用方式并入本文。
以下定义可适用于理解本公开：
“吸收制品”在本文中用于指主要功能为吸收和保留污垢和废物的消费品。“尿布”在本文中用于指一般由婴儿和失禁患者围绕下体穿着的吸收制品。术语“一次性的”在本文中用于描述通常不旨在洗涤、或者复原、或作为吸收制品再使用的吸收制品(例如，它们旨在在单次使用后丢弃，并且也可被构造成可回收利用、堆肥处理或换句话讲以其它与环境相容的方式进行处理)。
“弹性的”、“弹性体”或“弹性体的”在本文中是指如下任何材料，在向其松弛的初始长度施加力时所述材料能够拉伸或伸长至比其初始长度大超过10％的伸长长度，并且在释放所施加的力时将基本上恢复至大约其初始长度。
如本文所用，术语“接合”涵盖其中通过将一元件直接附连到另一元件而使该元件直接固定到另一元件上的构型，以及其中通过将一元件附连到中间构件而中间构件又被附连到另一元件而使该元件间接固定到另一元件上的构型。
“纵向”是指当制品处于平展未收缩状态时从吸收制品的腰部边缘到纵向相对的腰部边缘，或者在双折的制品中从腰部边缘到裆的底部(即折叠线)基本上垂直延伸的方向。在纵向的45度以内的方向被认为是“纵向”。“侧向”是指从制品的纵向延伸的侧边缘到侧向相对纵向延伸的侧边缘延伸的且与纵向大体成直角的方向。在侧向的45度以内的方向被认为是“侧向”。
“径向”是指从转筒的中心朝外圆周表面延伸的方向。
术语“基底”在本文中用于描述如下材料，所述材料主要为二维的(即在XY平面中)，并且其厚度(在Z方向上)与其长度(在X方向上)和宽度(在Y方向上)相比相对较小(即1/10或更小)。基底的非限制性实例包括纤维网、一层或多层或纤维材料、非织造材料、膜和箔片诸如聚合物膜或金属箔片。这些材料可单独使用或可包括两种或更多种层状材料。因此，纤维网为一种基底。
术语“非织造材料”在本文中是指采用如纺粘法、熔喷法、梳理成网等方法由连续(长)丝(纤维)和/或不连续(短)丝(纤维)制成的材料。非织造材料不具有纺织丝或编织丝模式。
术语“纵向”(MD)在本文中用于指加工过程中材料流的方向。此外，材料的相对放置和运动还能够被描述为在纵向上从工艺上游至工艺下游流动经过工艺。
本文所用术语“横向”(CD)是指不平行于且通常垂直于纵向的方向。
术语“裤”(也称为“训练裤”、“预闭合尿布”、“尿布裤”、“裤型尿布”、和“套穿尿布”)在本文中是指设计用于婴儿或成人穿着者的具有连续周边腰部开口和连续周边腿部开口的一次性吸收制品。在制品被穿用到穿着者之前，裤可被构造为具有连续或闭合的腰部开口和至少一个连续的闭合的腿部开口。裤可通过多种技术预成形，所述技术包括但不限于使用任何可重复扣紧的闭合构件和/或永久性闭合构件将制品的部分接合在一起(例如接缝、热粘结、压力焊接、粘合剂、胶粘剂粘结、机械扣件等)。裤可沿制品周围在腰区中的任何位置预形成(例如，侧边扣紧的或接缝的、前腰扣紧的或接缝的，后腰扣紧的或接缝的)。
“预扣紧的”在本文中是指以如下构型制造并提供给消费者的裤型尿布，其中在被应用到穿着者之前，前腰区和后腰区是扣紧的或在包装时是彼此连接的。因此，裤型尿布可具有被设计成用于婴儿或成人穿着者的连续周边腰部开口和连续周边腿部开口。如下文所更详细论述，尿布裤可通过各种技术来预成形，包括但不限于使用可重复扣紧的和/或永久性闭合构件将尿布的部分接合在一起(例如，接缝、热结合、压力焊接、粘合剂、胶粘剂结合、机械扣件等)。此外，裤型尿布还可在沿腰区周围的任何位置预成形(例如，侧边扣紧的或接缝的、前腰扣紧的或接缝的、后腰扣紧的或接缝的)。
本文所用“柔顺的”是指计示硬度介于20和100之间的任何材料，所述计示硬度是根据ASTM International Designation:D2240for Type Adurometers测量的。
本公开涉及用于将基底粘结在一起的方法和设备。如下文所更详述，粘结机设备可包括转筒和邻近转筒的砧辊。砧辊和转筒可各自包括外圆周表面。转筒也可包括外圆周表面中的孔和从所述转筒的外圆周表面径向向内定位的一个或多个接缝工位。砧辊的外圆周表面可包括柔顺材料。如下所更详述，接缝工位可包括与压制构件可操作地连接的流体喷嘴。在粘结操作期间，使转筒围绕旋转轴线旋转，并且第一基底层在纵向上推进到转筒的外圆周表面上。另外还在纵向上推进第二基底层，其中第一基底层位于第二基底层和转筒之间。将流体加热至足以至少部分地熔融基底的温度。当转筒的旋转时，流体喷嘴朝转筒的外圆周表面中的孔径向向外移动。流体喷嘴引导受热流体的射流穿过所述孔并到达第一基底层和第二基底层的重叠区域上，其部分地熔融所述重叠区域。当转筒继续旋转时，流体喷嘴从所述孔径向向内回缩，并且压制构件径向向外移动穿过所述孔。
所述部分地熔融的重叠区域随后被推进穿过形成于压制构件和砧辊之间的辊隙，从而在压制构件和砧辊之间压缩第一基底和第二基底的重叠区域。压制构件可抵靠砧辊压制重叠区域，使得砧辊的外圆周表面朝砧辊的旋转轴线径向向内变形。压制构件可按径向厚度使砧辊的外圆周表面变形，所述径向厚度为未压缩且未熔融的第一基底和第二基底层的厚度的至少25％。同时，第一基底和第二基底可在非切向于砧辊的外圆周表面和压制构件的外表面的方向上变形。因此，离散的粘结区域或接缝形成于第一基底和第二基底之间。接着，转筒继续旋转，并且压制构件从所述孔径向向内回缩。
应当理解，虽然本文的粘结方法和设备可被构造成粘结各种类型的基底，但下文在制造吸收制品的上下文中讨论本文的方法和设备。具体地，在如下的上下文中讨论这些方法和设备：在生产期间将带基底粘结在一起以在推进的连续长度的吸收制品上形成侧缝。如下所述，推进的连续长度的吸收制品可包括连接至连续的第一带基底和连续的第二带基底的多个基础结构。连续的第一带基底和第二带基底在沿纵向推进期间可沿横向彼此分开。每个基础结构可在横向上延伸并可包括由中心区分开的相对的第一端区和第二端区，其中第一端区连接至第一带基底并且第二端区连接至第二带基底。基础结构也可沿纵向彼此间隔开。
折叠设备操作以围绕折叠轴线沿中心区折叠基础结构，并且使第二带基底和基础结构的第二端区与第一带基底和基础结构的第一端区成面对关系。在一些示例性构型中，第一带基底、第二带基底、折叠的基础结构在纵向上推进到旋转的转筒诸如上述转筒的外圆周表面上。当转筒旋转时，流体喷嘴朝转筒的外圆周表面中的孔径向向外移动。流体喷嘴引导受热流体的射流穿过所述孔并到达第一带基底和第二带基底的重叠区域上，其部分地熔融所述重叠区域。当转筒继续旋转时，流体喷嘴从所述孔径向向内回缩，并且压制构件径向向外移动穿过所述孔。然后在压制构件和砧辊之间压缩所述部分地熔融的重叠区域，从而在第一带基底和第二带基底之间产生离散的粘接部位或接缝。转筒继续旋转，并且压制构件从所述孔径向向内回缩，并且将连续长度的第一带基底和第二带基底从转筒推进至刀辊。粘结区由刀辊沿横向切割以在吸收制品上产生第一侧缝和在随后推进的吸收制品上产生第二侧缝。
虽然以下讨论涉及粘结一个或多个基底层，但应当理解，在一些示例性构型中，本文所公开的设备和方法可用来压花或变形单一基底层。
本文所讨论的方法和设备可用来粘结各种类型的基底构型，它们中的一些可用于制造不同类型的吸收制品。为了有助于为过程构型的后续的讨论提供另外的上下文，下文提供了对呈尿布形式的吸收制品的一般描述，所述尿布包括可根据本文所公开的方法和设备粘结的部件。
图1和2A示出了尿布裤100的一个实例，其可根据本文所公开的设备和方法来装配和折叠。具体地，图1示出了处于预扣紧构型的尿布裤100的透视图，并且图2A示出了尿布裤100的平面图，其中尿布的背离穿着者的部分朝观察者取向。图1和2A所示的尿布裤100包括基础结构102和环状弹性带104。如下文所更详述，第一弹性带106和第二弹性带108连接在一起以形成环状弹性带104。
继续参见图2A，基础结构102包括第一腰区116、第二腰区118、以及设置在第一腰区和第二腰区之间的裆区120。第一腰区116可被构造为前腰区，并且第二腰区118可被构造为后腰区。在一些构型中，前腰区、后腰区、和裆区中的每个的长度可为吸收制品100的长度的1/3。尿布100也可包括前腰区116中的侧向延伸的前腰边缘121和后腰区118中的纵向相对且侧向延伸的后腰边缘122。为了为本讨论提供参照系，图2A中的尿布100和基础结构102被示出具有纵向轴线124和侧向轴线126。在一些示例性构型中，纵向轴线124可延伸经过前腰边缘121并经过后腰边缘122。并且侧向轴线126可延伸经过基础结构102的第一纵向或右侧边缘128并经过第二纵向或左侧边缘130的中点。
如图1和2A所示，尿布裤100可包括面向身体的内表面132、和面向衣服的外表面134。基础结构102可包括底片136和顶片138。基础结构102也可包括具有吸收芯142的吸收组件140，所述吸收芯设置在顶片138的一部分和底片136之间。如下文所更详述，尿布100也可包括其它特征结构诸如腿弹性部件和/或腿箍以增强围绕穿着者腿部的贴合性。
如图2A所示，基础结构102的周边可由下列限定：第一纵向侧边128、第二纵向侧边130、设置在第一腰区116中的第一侧向延伸的端边144、和设置在第二腰区118中的第二侧向延伸的端边146。侧边128和130均在第一端边144和第二端边146之间纵向延伸。如图2A所示，侧向延伸的端边144和146位于前腰区116中的侧向延伸的前腰边缘121和后腰区118中的侧向延伸的后腰边缘122的纵向内侧。当尿布裤100被穿着在穿着者下体上时，基础结构102的前腰边缘121和后腰边缘122可环绕穿着者腰部的一部分。同时，基础结构侧边缘128和130可环绕穿着者腿部的至少一部分。并且裆区120一般可定位在穿着者两腿之间，其中吸收芯142从前腰区116穿过裆区120延伸至后腰区118。
尿布裤可被制造成具有环状弹性带104并以如下构型提供给消费者，其中在被应用到穿着者之前，前腰区116和后腰区118在包装时是彼此连接的。因此，尿布裤可具有诸如图1所示的连续周边腰部开口110和连续周边腿部开口112。
环状弹性带104由连接至第二弹性带108的第一弹性带106限定。如图2A所示，第一弹性带106限定相对的第一和第二端区106a,106b以及中心区106c，并且第二弹性带108限定相对的第一和第二端区108a,108b以及中心区108c。
第一弹性带的中心区106c与基础结构102的第一腰区116连接，并且第二弹性带108的中心区108c与基础结构102的第二腰区116连接。如图1所示，第一弹性带106的第一端区106a在第一侧缝178处与第二弹性带108的第一端区108a连接，并且第一弹性带106的第二端区106b在第二侧缝180处与第二弹性带108的第二端区108b连接，从而限定环状弹性带104以及腰部开口110和腿部开口112。第一弹性带106可限定内表面117a和外表面119a。第二弹性带108可限定内表面117b和外表面119b。
如图2A，3A和3B所示，第一弹性带106也限定外侧向边缘107a和内侧向边缘107b，并且第二弹性带108限定外侧向边缘109a和内侧向边缘109b。外侧向边缘107a,107b也可限定前腰边缘120和侧向延伸的后腰边缘122。第一弹性带和第二弹性带也可各自包括面向衣服的外层层162和面向穿着者的内层164。应当理解，第一弹性带106和第二弹性带108可包括相同的材料和/或可具有相同的结构。在一些示例性构型中，第一弹性带106和第二弹性带可包括不同的材料和/或可具有不同的结构。还应当理解，第一弹性带106和第二弹性带108可由各种材料构造成。例如，第一带和第二带可由如下材料制成：诸如塑料膜；开孔塑料膜；天然材料(例如，木纤维或棉纤维)、合成纤维(例如，聚烯烃、聚酰胺、聚酯、聚乙烯、或聚丙烯纤维)或天然纤维和/或合成纤维的组合的织造幅材或非织造幅材；或带涂层的织造或非织造纤维网。在一些示例性构型中，第一弹性带和第二弹性带包括合成纤维的非织造纤维网，并且可包括可拉伸的非织造材料。在其它示例性构型中，第一弹性带和第二弹性带包括内疏水的不可拉伸的非织造材料和外疏水的不可拉伸的非织造材料。
第一弹性带106和第二弹性带108也可各自包括插置在外层162和内层164之间的带弹性材料。带弹性材料可包括一个或多个弹性元件诸如沿弹性带的长度延伸的股线、带状物、或板。如图2A，3A和3B所示，带弹性材料可包括多根弹性股线168，它们在本文中可称作外腰弹性部件170和内腰弹性部件172。如图2A所示，弹性股线168在第一弹性带106的相对的第一和第二端区106a,106b之间且在第二弹性带108的相对的第一和第二端区108a,108b之间连续地侧向延伸。在一些示例性构型中，一些弹性股线168可被构造成在区域中具有中断部分，例如，在第一弹性带106和第二弹性带108重叠吸收组件140的区域中。在一些示例性构型中，弹性股线168可沿纵向以恒定间隔设置。在其它示例性构型中，弹性股线168可沿纵向以不同间隔设置。处于拉伸状态的带弹性材料可插置并接合于在未收缩的外层和未收缩的内层之间。当带弹性材料松弛时，带弹性材料恢复至未拉伸状态并使外层和内层收缩。带弹性材料可在环状弹性束带的区域中提供收缩力的所期望的变化。
应当理解，可以除如图2A所示方式之外的不同方式来构造基础结构102和弹性带106,108。例如，图2B示出了尿布裤100的平面图，所述尿布裤具有与上文参考图2A所述的相同的组件，不同的是基础结构102的第一侧向延伸的端边144沿第一弹性带106的外侧向边缘107a对齐并与其重合，并且第二侧向延伸的端边146沿第二带108的外侧向边缘109a对齐并与其重合。
根据本公开的设备和方法可用来装配预扣紧的、可重复扣紧的裤型尿布100的各种部件。例如，图4示出了适于制造裤型尿布100的转换加工设备300的示意图。可参照上文所述且图1和2A所示的裤型尿布100的所述各种组件来描述转换加工设备300的操作方法。虽然以下方法是在图1和2A所示尿布100的上下文中提供的，但应当理解，可根据本文所公开的方法制造出尿布裤的各种构型，例如以下专利中所公开的吸收制品：2004年11月10日提交的美国专利7,569,039；2004年11月10日提交的美国专利公布2005/0107764A1；2011年8月30日提交的美国专利申请13/221,127；和2011年8月30日提交的美国专利申请13/221,104。
如下文所更详述，图4所示的转换加工设备300操作以沿纵向MD推进离散的基础结构102，使得每个基础结构102的侧向轴线平行于纵向，并且其中基础结构102沿纵向MD彼此间隔开。间隔开的基础结构102的相对的腰区116,118随后连接至推进的连续长度的第一弹性带基底406和第二弹性带基底408。然后沿侧向轴线折叠基础结构102以使第一弹性带基底406和第二弹性带基底408成面对关系，并且第一弹性带基底和第二弹性带基底沿间歇地沿纵向间隔开的区336连接在一起。每个区336均可包括一个或多个离散的粘结部位336a。然后沿区336切割弹性带基底406,408以产生离散的尿布100，诸如图1所示。
如图4和5A所示，在纵向MD上将连续长度的基础结构组件302推进至载体设备308并用刀辊306切割成离散的基础结构102。连续长度的基础结构组件可包括腿弹性部件、阻隔腿箍、夹置在顶片材料138和底片材料136之间的吸收组件140等。基础结构组件的一部分被切除以示出顶片材料138的一部分和吸收组件140。
在使用刀辊306切割了离散的吸收基础结构102之后，载体设备308旋转并在纵向MD上以图5B1所示的取向推进离散的基础结构102，其中基础结构102的纵向轴线124大致平行于纵向MD。虽然图5B1所示的基础结构102被示出具有作为前缘的第二侧向延伸的端边146和作为后缘的第一侧向延伸的端边144，但应当理解，在其它构型中，可按其它取向来推进基础结构102。例如，基础结构可取向成使得第二侧向延伸的端边146成为后缘并且第一侧向延伸的端边144成为前缘。载体设备308也旋转，同时改变推进的基础结构102的取向。载体设备308也可改变基础结构102在纵向MD上推进的速度。应当理解，各种形式的载体设备与本文的方法一起使用，例如，美国专利7,587,966所公开的载体设备。图5B2示出了基础结构102在纵向上推进时在载体设备308上的取向。更具体地，图5B2示出了如下基础结构102，其中基础结构102的侧向轴线126大致平行于纵向MD，并且其中第二纵向侧边130为前缘且第一纵向侧边128为后缘。
如下文参照图3,5C,5D,5E和5F所述，基础结构102从载体设备308上转移并且与推进的连续长度的带基底406,408组合，所述带基底随后被切割以形成尿布100上的第一弹性带106和第二弹性带108。
参考图4和5C，基础结构102从载体设备308转移至载体设备308和载体设备318之间的辊隙316，在该辊隙处基础结构102与推进的连续长度的前带406基底和后带408基底组合。前带基底406和后带基底408各自限定面向穿着者的表面312和相对的面向衣服的表面314。第一带基底406的面向穿着者的表面312可沿第一腰区116与基础结构102的面向衣服的表面134组合，并且第二带基底408的面向穿着者的表面312可沿第二腰区118与基础结构102的面向衣服的表面134组合。如图4所示，在与离散的基础结构102组合之前，在辊318和载体设备308之间的辊隙316处，可将粘合剂320间歇地施加到第一带基底406和第二带基底408的面向穿着者的表面312上。
参考图4和5D，连续长度的吸收制品400由多个离散的基础结构102限定，所述多个离散的基础结构沿纵向MD彼此间隔开并通过第二带基底408和第一带基底406彼此连接。如图4所示，连续长度的吸收制品400从辊隙316推进至折叠设备500。在折叠设备500处，在横向CD上沿侧向轴线126折叠每个基础结构102以将第一腰区116(具体地，面向身体的内表面132)放置成与第二腰区118的身体的内表面132成面对的表面对表面取向。基础结构的折叠也将在每个基础结构102之间延伸的第二带基底408的面向穿着者的表面312定位成与在每个基础结构102之间延伸的第一带基底406的面向穿着者的表面312成面对关系。参见图4,5D和5E，与第一带基底406和第二带基底408连接的折叠的离散的基础结构102从折叠设备500被推进至粘结机设备334。粘结机设备334操作以粘结重叠区域362，因此产生离散的粘结部位336a。重叠区域362包括第一基底层407和第二基底层409，它们在图5G中分别被示出为在每个基础结构102之间延伸的第二带基底408的一部分和在每个基础结构102之间延伸的第一带基底406的一部分。重叠区域362可由如图5G所示的厚度C限定。厚度C为未压缩且未熔融的第一基底406和第二基底408的组合厚度，诸如图5G所示。参见图4和5F，连续长度的吸收制品从粘结机334被推进至刀辊338，在该刀辊处沿横向切入区336以在吸收制品100上产生第一侧缝178并在随后推进的吸收制品上产生第二侧缝180。
虽然吸收制品被描述为具有第一带基底和第二带基底，但应当理解，吸收制品可具有仅一个带基底。另外，还应当理解，吸收制品的基础结构和带基底可为一个连续基底，使得重叠区域由相同的基底形成。因此，粘结机设备可操作以在重叠区域处粘结连续基底以形成一个或多个离散的粘结部位。
参考图4，转换加工设备可包括粘结机设备334。例如，图6A示出了可与本文的方法和设备一起使用的粘结机设备334的详细的示意性侧视图。如图6A所示，粘结机设备334可包括转筒364和邻近转筒364定位的砧辊368。砧辊368包括外圆周表面370并且适于围绕旋转轴线372旋转。包括外圆周表面370的砧辊368可包括柔顺材料。转筒364也可包括外圆周表面376并且适于围绕旋转轴线374旋转。转筒364可包括位于外圆周表面376中的一个或多个转筒孔366。此外，多个缝接工位348从外圆周表面376和转筒孔366径向向内定位。如下所更详述，参照图6B，每个接缝工位348可包括流体喷嘴378和压制构件380。虽然图6A所示的转筒364包括六个接缝工位348，但应当理解，转筒364可被构造成包括多于或少于六个接缝工位348。
在操作期间，转筒364可在图6A所示的方向上围绕旋转轴线374旋转，并且砧辊368可在图6A所示的方向上围绕旋转轴线372旋转。吸收制品400可在纵向MD上推进到外圆周表面376上，其中第一带基底406位于第二带基底408和外圆周表面376之间。当转筒364旋转时，缝接工位348的流体喷嘴378朝位于外圆周表面376中的转筒孔366径向向外移动，如图6B所示。将流体加热至足以至少部分地熔融重叠区域的温度。流体喷嘴378引导受热流体的射流穿过转筒孔366并到达第一基底406和第二基底408的重叠区域上以部分地熔融重叠区域。
参见图6A和6B，当转筒364继续旋转时，流体喷嘴378从转筒孔366径向向内回缩，转筒112继续围绕旋转轴线374旋转，并且压制构件径向向外移位穿过转筒孔366。吸收制品400随后穿过形成于压制构件380和砧辊368之间的辊隙332，如图6A所示。压制构件380抵靠外圆周表面370压缩所述部分地熔融的重叠区域，从而在第一带基底406和第二带基底408之间产生一个或多个离散的粘结部位336a。当压制构件380抵靠外圆周表面370压缩所述部分地熔融的重叠区域时，压制构件380可朝旋转轴线372使砧辊368的外圆周表面370径向向内变形。同时，第一基底406和第二基底408的重叠区域在非切向于压制构件380的外表面425和砧辊368的外圆周表面370的方向Z上被变形，如下文所更详述。因此，当吸收制品400推进穿过辊隙332时，压制构件380压缩重叠区域的时间多于一瞬间。转筒364继续旋转，并且压制构件从转筒孔366径向向内回缩。
转筒的每个缝接工位均可包括流体喷嘴和压制构件。图7示出了缝接工位348的详细分解图。如图7所示，接缝工位348包括基座构件340，所述基座构件固定地与转筒连接并与其一起旋转。基座构件340为基本上正方形的并且由基座构件顶部表面382和基座构件底部表面383限定。基座构件340包括基座孔350，所述基座孔延伸穿过基座构件顶部表面382和底部表面383，使得流体喷嘴384和压制构件380可延伸穿过基座孔350。此外，基座构件底部表面383与基座联接件352固定地连接。如下所述，基座联接件352的一个端部连接至基座构件底部表面383，并且基座联接件352的另一个端部可操作地连接至第一移位联接件354。
继续参见图7，接缝工位348也包括凸轮从动件构件358以及与凸轮从动件构件358滚动地连接的第一组凸轮滚柱388和第二组凸轮滚柱390。凸轮从动件构件358为基本上T形的，并且由凸轮从动件构件第一部分360、凸轮从动件构件第二部分362、和凸轮从动件构件顶面363限定。凸轮从动件构件第一部分360在凸轮从动件构件358上相同的位置可操作地与第一移位联接件354和第一组凸轮滚柱388连接。此外，第二组凸轮滚柱390在第一组凸轮滚柱388的径向外侧的位置可操作地连接到凸轮从动件构件第二部分362。一组第二移位联接件356也可操作地连接至凸轮从动件构件358。该组第二移位联接件356在第二组凸轮滚柱390相对外侧的位置将基座构件340可操作地连接至凸轮从动件构件第一部分360。
如下所更详述，参照图6A1和6B，第一组凸轮滚柱388和第二组凸轮滚柱390被构造成在转筒364旋转时沿固定式凸轮轨道滚动。固定式凸轮轨道293围绕旋转轴线374并且由内圆周表面395和半径R限定，所述半径从固定式凸轮轨道392的内圆周表面395延伸至旋转轴线374，如图6A1所示。在一些示例性构型中，固定式凸轮轨道392可包括各种弯曲区和/或直区，使得固定式凸轮轨道392在沿固定式凸轮轨道392的内圆周表面395的不同点由相对较长和较短的半径R限定。当转筒364旋转时，第一组凸轮滚柱388和第二组凸轮滚柱390在固定式凸轮轨道392上滚动。第一移位联接件354、第二移位联接件356、和第三移位联接件385枢转，其中固定式凸轮轨道392的半径R随着第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392的滚动而增加或减小。同时，在其中固定式凸轮轨道392由相对较长半径R限定的区域中，凸轮从动件构件385径向向外移位穿过基座孔。而在其中固定式凸轮轨道392由相对较短半径R限定的区域中，凸轮从动件构件径向向内移位穿过基座孔。应当理解，凸轮轨道392可被构造成具有各种其它形状和尺寸。例如，在一些示例性构型中，凸轮轨道392可被构造成具有相对于旋转轴线374偏置或偏心的圆形形状。从该旋转轴线偏置固定式凸轮轨道导致凸轮从动件构件随着第一组凸轮滚柱和第二组凸轮滚柱沿固定式凸轮轨道滚动而移位。
参照图7和8，接缝工位348可还包括弹簧构件394。弹簧构件394可为基本上U形的并且由弹簧构件顶面410、弹簧构件底面411、和弹簧构件侧开口412限定。参照图7，弹簧构件底面411固定地连接至凸轮从动件构件顶面363。弹簧构件394可沿整个凸轮从动件构件顶面363延伸。如下文所述更详述，当压制构件抵靠外圆周表面压缩所述部分地熔融的重叠区域时，弹簧构件侧开口412允许弹簧构件394挠曲。
缝接工位也可包括压制构件380，如图7所示。压制构件380可为基本上矩形的形状，并且由压制构件顶面420、压制构件底面421、和压制构件长度387限定。压制构件380可包括基本上正方形的突出部423，所述突出部从压制构件顶面420向外延伸。突出部423可由外表面425限定，所述外表面为突出部423的径向最外侧表面。在一些示例性构型中，突出部423可具有平坦外表面425，如图6B所示。然而，在其它示例性构型中，突出部423可具有弯曲外表面。压制构件底面421固定地连接至弹簧构件顶面410。压制构件380可沿整个弹簧构件顶面410延伸。如下所更详述，突出部423可被布置成两行，如图7所示。突出部423可包括柔顺材料，所述柔顺材料可形成突出部423的外表面425。
继续参见图7，缝接工位348也可包括加热设备384。如下所更详述，每个加热设备384均提供加压流体源以用于向例如流体喷嘴378递送受热的加压流体诸如空气。在一些示例性构型中，阀门可控制流体从加热设备384流出并进入到流体喷嘴378中。每个加热设备384均由一组第三移位联接件385可操作地连接至基座构件340。每个第三移位联接件385均可操作地连接至一个加热设备384的一个端部并且也连接至凸轮从动件构件第二部分365。
参考图7，缝接工位也可包括流体喷嘴378。流体喷嘴378可包括一个或多个流体孔口424，在该流体孔口处从流体喷嘴378释放出受热的加压流体。每个加热设备384均固定地与分隔的流体喷嘴378连接。如图7所示，流体孔口424可为圆形的并且可成行地沿流体喷嘴378延伸。
参见图6A和9，砧辊368可包括柔顺材料342。柔顺材料342可限定砧辊368的外圆周表面370。柔顺材料可包括例如硅氧烷、天然橡胶、合成橡胶(例如，Buna-N、Buna-S、腈、和氯丁橡胶)、聚氨酯、ABS塑料。柔顺材料可具有在20-100计示硬度的肖氏硬度A标度范围内的计示硬度或等同的计示硬度。在一些示例性构型中，柔顺材料342可形成砧辊368上的套筒343，如图6A所示。套筒343可限定砧辊368的外圆周表面370。在一些示例性构型中，砧辊368可完全由柔顺材料构成。
在操作中，吸收制品在纵向MD上被推进至粘结机设备334。参考图6A，当转筒364围绕旋转轴线374旋转时，吸收制品400在纵向MD上推进到外圆周表面376上。第一带基底406位于第二带基底408和外圆周表面376之间。更具体地，第一带基底406的外层162可直接接触外圆周表面376。并且第一带基底406的内层164可直接接触第二带基底408的内层164。外圆周表面376以与推进的吸收制品400相同的速度行进，使得吸收制品400在外圆周表面376上被接收的位置保持恒定，直到吸收制品400从转筒364下游被移除。第一带基底406和第二带基底408的重叠区域被定位在与转筒孔366一致的外圆周表面376上。如下所更详述，从转筒孔366径向向内定位的接缝工位348被构造成在吸收制品400沿转筒364行进时粘结重叠区域的一部分。当吸收制品被接收在转筒364上时，接缝工位348被布置成处于第一构型。
图10示出了处于第一构型的缝接工位348的透视图。参考图8和10，在第一构型中，流体喷嘴378径向向外定位靠近转筒孔366和外圆周表面376，而压制构件380径向向内定位远离转筒孔366和外圆周表面376。此外，流体喷嘴378定位在与压制构件380的突出部423相同的圆周位置处，使得受热流体被引导至重叠区域上相同的位置，所述重叠区域随后将被压制构件380压缩。
参考图6A和6B，当转筒364继续旋转时，吸收制品400围绕外圆周表面376包裹。同时，受热的加压流体的射流从加热设备384被引导出流体喷嘴378并到达第一带基底406和第二带基底408的重叠区域上。保持流体喷嘴378与第一带基底406的外层162相距预选距离Y以控制由受热流体施加于重叠区域的压力，如图6B1所示。在一些示例性构型中，第一带基底406的外层162和流体喷嘴378之间的距离Y可保持在所述预选距离Y的3mm内。
当流体加热重叠区域时，可使用位置控制设备将吸收制品保持在与转筒的外圆周表面相距的恒定距离内。在一些示例性构型中，位置控制设备450可为带设备451，如图11所示。位置控制设备450可邻近转筒364定位，并且可采用外圆周表面376的至少一部分的形状。位置控制设备可使吸收制品400保持在与转筒的外圆周表面相距0毫米至约10毫米的范围内，或与外圆周表面相距介于约0.5毫米至约5毫米之间。
一旦重叠区域被至少部分地熔融，并且当转筒364继续旋转时，接缝工位移位至第二构型。参考图6A,6A1,6B和6B1，当转筒364旋转时，第一组凸轮滚柱388和第二组凸轮滚柱390在固定式凸轮轨道392上滚动。当第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392滚动时，固定式凸轮轨道392保持固定。当第一组凸轮滚柱388和第二组凸轮滚柱390从其中固定式凸轮轨道392的半径R由相对较短半径R限定的区域滚动至其中固定式凸轮轨道392的半径R由相对较长半径R限定的区域时，第一移位联接件354、第二移位联接件356、和第三移位联接件385枢转。参照图6B，第一移位联接件354在基座联接件352和凸轮从动件构件358处枢转，而该组第二移位联接件356在凸轮从动件构件358和基座构件340处枢转。同时，凸轮从动件构件358朝外圆周表面376径向向外移位。第三移位联接件385也在凸轮从动件构件358处枢转，导致加热设备384远离外圆周表面376径向向内移动，并且导致流体喷嘴378在圆周上彼此分开地铺展在压制构件380的任一侧上。接缝工位348继续移位，直到第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392的区域滚动，在所述区域中固定式凸轮轨道392的半径R保持恒定，这对应于接缝工位348的第二构型。接缝工位348保持在第二构型，直到第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392行进至其中固定式凸轮轨道由相对较短的半径限定的区域。
图12示出了处于第二构型的缝接工位348的透视图。参考图12，在第二构型处，压制构件380延伸穿过转筒孔而超过外圆周表面，加热设备384径向向内定位远离转筒孔366，并且流体喷嘴378邻近外圆周表面366位于凸轮从动件构件的任一侧上。
参照图6A和6B，当转筒364继续旋转并且接缝工位348处于第二构型时，所述部分地熔融的重叠区域接近邻近转筒364定位的砧辊368。当吸收制品400推进穿过形成于砧辊368和转筒364之间的辊隙332时，从转筒孔366径向向外延伸的压制构件380抵靠外圆周表面370压缩所述部分地熔融的重叠区域。如图9和13-15所示，当吸收制品400推进穿过旋转的砧辊368和缝接工位348的压制构件380之间的辊隙332时，压制构件380的突出部423朝旋转轴线372使砧辊368的外圆周表面370径向向内变形。因此，第一基底406和第二基底408在方向Z上变形，所述方向非切向于砧座368的外圆周表面370和压制构件380的突出部423的外表面425。
砧辊368可被构造成在朝旋转轴线372的方向上按径向厚度RT变形，所述径向厚度为合并的未压缩且未熔融的第一基底406和第二基底408的厚度C的至少25％。在一些示例性构型中，砧辊368可按径向厚度RT变形，所述径向厚度为合并的未压缩且未熔融的第一基底406和第二基底408的厚度C的至少30％，至少40％，至少50％，至少60％，至少70％，至少80％。
压制构件380的突出部423被构造成接触重叠区域的相同的位置，所述重叠区域如图6B所示被受热流体至少部分地熔融，因此在重叠区域中形成离散的粘结部位336a。弹簧构件394可用来向压制构件380和砧辊368之间的重叠区域施加预先确定的力。一旦被压缩，吸收制品就推进而脱离转筒外周边。转筒继续旋转，并且接缝工位移位回到第一构型以便在后续的吸收制品中形成离散的粘结部位。
在一些示例性构型中，从吸收制品至流体喷嘴的距离可在0毫米至约20毫米，或例如介于约0毫米和约5毫米之间，或介于约0.5毫米和约3毫米之间的范围内。控制第一基底和第二基底与流体孔口424之间的距离也可在加热过程中导致相对更可预测的流体喷涂和熔体图案。
受热流体可包括环境空气或其它气体。应当理解，流体可被加热至各种温度并被加压至各种压力。例如，在一些示例性构型中，流体可被加热多至第一带基底和第二带基底的较低熔点减30℃至第一带基底和第二带基底的较低熔点加100℃的温度的范围内。在一些示例性构型中，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。在一些示例性构型中，可朝第一带基底和第二带基底中的至少一者引导受热流体并持续范围为10至1000毫秒或更长的时间间隔。可使用更短或更长的时间间隔。
在一些示例性构型中，压制构件可按在约1×105牛顿/平方米至约1×108牛顿/平方米的范围内的压力抵靠外圆周表面压缩所述部分地熔融的重叠区域。在一些示例性构型中，压制构件366可压缩第一带基底和第二带基底并持续范围为10至1000毫秒或更长的时间段。可使用更短或更长的时间间隔。
参见图10，应当理解，突出部423在各种构型中可规则地或不规则地间隔开，并且可在各种方向上取向。突出部423可具有圆形、椭圆形、或各种其它形状。在一些示例性构型中，压制构件的突出部可具有平滑表面，使得离散的粘结部位将是平坦的。然而，在一些示例性构型中，压制构件的突出部可具有粗糙表面，使得离散的粘结部位将具有纹理。参照图10，突出部423可具有在约0.5毫米至约5毫米的范围内的高度440。在一些示例性构型中，突出部可具有在约2毫米至约10毫米，或在约4毫米至约6毫米之间的范围内的宽度442。
虽然图8和12示出了弹簧构件390具有U形状，但应当理解，可使用各种其它弹簧构件来吸收来自压制构件380的压力，所述压制构件压缩外圆周表面之间的重叠区域。通过控制施加于重叠区域的力的量，有可能施加足以形成离散的粘结部位的力以最小化对基底的损害和/或尽量避免形成相对弱的离散的粘结件。
一旦选择了标称设定点，流体的温度和压力就保持在指定范围内。例如，可从上述范围选择设定值，因而温度可保持在围绕标称设定值的固定范围内，诸如±30℃，并且压力可保持在围绕标称设定值的固定范围内，诸如±1巴。可接受的范围将取决于要接合的材料的特性诸如软化点和/或熔融温度和所选择的标称设定值之间的关系。例如，高于要接合的材料中的一者或多者的熔融温度的标称设定值与远远低于要接合的一种或多种材料的熔融温度的标称设定值相比可需要较紧密的控制范围。控制范围可为关于标称设定值非对称的。所谓充分地加热，是指流体被加热至将使得一个基底或多个基底能够至少部分地熔融或至少软化的温度。足够的加热可随着所用的材料和设备而变化。例如，如果几乎立即将受热流体施加于一个基底或多个基底而只有极少时间或没有时间冷却，则可将流体加热至一个或多个基底的大约软化点或大约熔点。如果在经过了某段时间或距离之后将受热流体指引至一个或多个基底，使得受热流体在与一个或多个基底相互作用之前可在一定程度上冷却，则可有必要将流体加热至高于(有可能显著地高于)一个或多个基底的软化点或熔点。
本文所述过程中的能量传递的持续过程可为动态过程，并且可产生在可熔融组件的横截面上的温度梯度。即，可熔性组件的芯可保持为固体，而可熔性组件的外表面熔融或接近熔融。甚至在低于熔融温度时，所述外表面也可达到软化点，使得与相同的材料在环境温度下的情况相比，材料的塑性变形可在低得多的负荷下发生。因此，如果要接合的材料中的一者或多者具有软化点，则可调节该过程以在第一带基底406和第二带基底408的至少一部分中获得软化点和熔点之间的温度。使用等于或高于可熔融组件中的一者或多者的软化点但低于熔点的温度可允许在第一带基底406和第二带基底408之间产生强效粘结，而对可熔融组件的结构的破坏(例如，拉细或以其他方式弱化可熔融组件)较小。
参照图4和5F，一旦形成了离散的粘结部位336a，吸收制品400就在纵向MD上推进至刀辊338，在该刀辊处沿横向切入区域336以在吸收制品100上产生第一侧缝178并在随后推进的吸收制品上产生第二侧缝180。在一些示例性构型中，应当理解，刀辊可与压制构件成一体，使得当压制构件压缩重叠区域时，压制构件也切割重叠区域。
在一些示例性构型中，压制构件580可呈旋转转筒520的形式。如图16所示，旋转转筒520可具有外圆周表面522和从旋转转筒520的外圆周表面522径向向外延伸的多个突出部523。在这种示例性构型中，具有外圆周表面570的砧辊568可邻近旋转转筒520定位，从而在所述砧辊和所述转筒之间形成辊隙532。砧辊568可包括柔顺材料。在其它示例性构型中，砧辊668可具有位于外圆周表面670中的多个孔534，诸如图17所示。孔534可被构造成与旋转转筒520的突出部523配合。在一些示例性构型中，图17所示的砧辊668可由刚性材料诸如金属制成。
在其它示例性构型中，压制构件780可呈第一传送装置720的形式，如图18所示。第一传送装置720可具有外表面722和从第一传送装置720的外表面722向外延伸的多个突出部723。砧辊730可被构造为第二传送装置740，其可邻近第一传送装置720定位，从而在所述砧辊和所述第一传送装置之间形成辊隙732。第二传送装置740可具有外表面742。第二传送装置740可包括柔顺材料。在其它示例性构型中，第二传送装置840可具有位于外表面842中的多个孔834，诸如图19所示。第二传送装置840的孔736可被构造成与第一传送装置720的突出部723配合。在一些示例性构型中，图19所示的第二传送装置840可由刚性材料诸如金属制成。
应当理解，本文所公开的方法和设备可与各种缝接设备一起使用。例如，本文所公开的方法和设备可与2012年2月22日提交的美国专利申请13/401,907和2012年2月22目提交的美国专利申请13/402,056一起使用。
虽然是在粘结带以制备侧缝的上下文中描述粘结机设备的，但应当理解，本文的方法和设备可用来将各种部件和基底粘结在一起。本文所公开的用于粘结基底的设备和方法也可被构造成根据2010年6月7日提交的美国专利6,248,195和美国专利申请公布2012-0021186所公开的设备和方法来操作。
本文所公开的量纲和值不应理解为严格限于所引用的精确值。相反，除非另外指明，每个这样的量纲旨在表示所述的值以及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”。
除非明确排除或换句话讲有所限制，本文中引用的每一个文件，包括任何交叉引用或相关专利或专利申请，均据此以引用方式全文并入本文。对任何文献的引用均不是承认其为本文公开的或受权利要求书保护的任何发明的现有技术、或承认其独立地或以与任何其它一个或多个参考文献的任何组合的方式提出、建议或公开任何此类发明。此外，当本文献中术语的任何含义或定义与以引用方式并入的文献中相同术语的任何含义或定义冲突时，应以本文献中赋予该术语的含义或定义为准。
尽管已用具体实施例举例说明和描述了本发明，但对于本领域中技术人员将显而易见的是，在不脱离本发明的实质和范围的情况下可作出多种其它的改变和修改。因此，所附权利要求书旨在涵盖本发明范围内的所有此类改变和修改。

Claims (15)

1.一种用于形成接缝的方法，所述方法包括以下步骤：
围绕旋转轴线(374)旋转转筒(364)，所述转筒(364)包括流体喷嘴(378)和压制构件(380)，所述压制构件(380)具有外表面(425)；
围绕旋转轴线(372)邻近所述转筒(364)旋转砧辊(368)，所述砧辊(368)具有柔顺外圆周表面(370)，所述砧辊(368)和所述转筒(364)在它们之间形成辊隙(332)；
在纵向(MD)上将第一基底层(407)推进到所述转筒(364)上，所述第一基底层(407)具有内表面和外表面，其中所述第一基底层(407)的外表面邻近所述转筒(364)；
在所述纵向(MD)上推进第二基底层(409)，所述第二基底层(409)具有内表面和外表面，其中所述第一基底层(407)位于所述第二基底层(409)和所述转筒(364)之间，其中所述第一基底层和第二基底层(407,409)具有合并的未压缩厚度(C)；
围绕所述转筒(364)的一部分包裹所述第一基底层和第二基底层(407,409)；
将流体加热至足以至少部分地熔融所述第一基底层和第二基底层(407,409)的温度；
相对于所述转筒(364)的旋转轴线(374)径向向外移动所述流体喷嘴(378)；
将所述受热流体的射流引导到所述第一基底层和第二基底层(407,409)上；
部分地熔融所述第一基底层和第二基底层(407,409)；
相对于所述转筒(364)的旋转轴线(374)径向向内回缩所述流体喷嘴(378)；
相对于所述转筒(364)的旋转轴线(374)径向向外移位所述压制构件(380)；
推进所述第一基底层和第二基底层(407,409)穿过所述辊隙(332)；以及
在所述压制构件(380)和所述砧辊(368)之间压缩所述第一基底层和第二基底层(407,409)以及使所述砧辊(368)的柔顺外圆周表面(370)变形。
2.根据权利要求1所述的方法，其中所述砧辊(368)以所述第一基底层和第二基底层(407,409)的合并的未压缩厚度(C)的至少约25％的径向厚度变形。
3.根据前述权利要求中任一项所述的方法，其中所述砧辊(368)以所述第一基底层和第二基底层(407,409)的合并的未压缩厚度(C)的至少约50％的径向厚度变形。
4.根据前述权利要求中任一项所述的方法，其中所述砧辊(368)包括套筒(343)，其中所述套筒(343)形成所述砧辊(368)的外圆周表面(370)。
5.根据权利要求4所述的方法，其中所述砧辊(368)的柔顺外圆周表面(370)具有约20至约100的肖氏硬度A计示硬度。
6.根据前述权利要求中任一项所述的方法，其中所述转筒(364)包括外圆周表面(376)和位于所述外圆周表面(376)中的转筒孔(366)，并且其中所述流体喷嘴(378)和压制构件(380)从所述外圆周表面(376)中的孔(366)径向向内定位。
7.根据前述权利要求中任一项所述的方法，其中所述压制构件(380)在所述砧辊(368)之间以约1×105牛顿/平方米至约1×108牛顿/平方米的压力压缩所述第一基底层和第二基底层(407,409)。
8.根据前述权利要求中任一项所述的方法，其中所述压制构件(380)包括多个突出部(423)，所述突出部(423)具有外表面(425)，其中在所述压制构件(380)和所述砧辊(368)之间压缩所述第一基底层和第二基底层(407,409)的所述步骤包括在所述压制构件(380)的突出部(423)和所述砧辊(368)之间压缩所述第一基底层和第二基底层(407,409)。
9.根据前述权利要求中任一项所述的方法，还包括利用刀辊(338)将所述第一基底层和第二基底层(407,409)切割成单个制品(100)的步骤。
10.一种用于将第一基底和第二基底(406,408)粘结在一起的设备，其中所述第一基底和第二基底(406,408)具有合并的未压缩厚度(C)，所述设备包括：
转筒(364)，所述转筒包括外圆周表面(376)和位于所述外圆周表面(376)中的转筒孔(366)，其中所述转筒(364)适于围绕旋转轴线(374)旋转；
可移动地连接至所述转筒(364)的流体喷嘴(378)，所述流体喷嘴相对于所述转筒孔(366)径向向内定位并适于径向向外引导流体穿过所述转筒孔(366)；
砧辊(368)，所述砧辊包括邻近所述转筒(364)定位的外圆周表面(370)以便在所述砧辊(368)和所述转筒(364)之间限定辊隙(332)，所述砧辊(368)适于围绕旋转轴线(372)旋转，所述砧辊(368)包括限定所述砧辊(368)的外圆周表面(370)的柔顺套筒(343)，其中所述砧辊(368)的外圆周表面(370)能够朝所述砧辊(368)的旋转轴线(372)变形；和
可移动地连接至所述转筒(364)的压制构件(380)，所述压制构件相对于所述转筒孔(366)径向向内定位并适于延伸穿过所述转筒孔(366)。
11.根据权利要求10所述的设备，其中所述砧辊(368)被构造成以所述第一基底和第二基底(406,408)的合并的未压缩厚度(C)的至少约25％的径向厚度变形。
12.根据权利要求10至11所述的设备，其中所述套筒(343)被构造成以所述第一基底和第二基底(406,408)的合并的未压缩厚度(C)的至少50％的径向厚度变形。
13.根据权利要求10至12中任一项所述的设备，其中所述砧辊(368)的柔顺外圆周表面(370)具有约20至约100的肖氏硬度A计示硬度。
14.根据权利要求10至13中任一项所述的设备，其中所述压制构件(380)包括相对于所述旋转轴线(374)径向向外延伸的突出部(423)，其中所述突出部(423)限定外表面(425)。
15.根据权利要求10至14中任一项所述的设备，其中所述压制构件(380)和所述砧辊(368)被构造成在非切向于所述突出部(423)的外表面(425)的方向上使所述第一基底和第二基底(406,408)变形。
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