CN1064238A - 增量拉伸零应变拉伸叠层坯料使其产生弹性的方法和装置 - Google Patents

增量拉伸零应变拉伸叠层坯料使其产生弹性的方法和装置 Download PDF

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CN1064238A
CN1064238A CN92101347.7A CN92101347A CN1064238A CN 1064238 A CN1064238 A CN 1064238A CN 92101347 A CN92101347 A CN 92101347A CN 1064238 A CN1064238 A CN 1064238A
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G·M·韦伯
小·W·R·文内治
D·H·本森
D·A·萨巴泰利
J·W·理查森
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Abstract

一种增量拉伸“零应变”拉伸叠层坯料使它产生 弹性的改进方法和装置。这种“零应变”叠层材料至 少由两层材料组成。这两层材料至少沿其共同扩张 表面在基本未拉伸(“零应变”)的条件下彼此间断地 或基本连续地固定在一起。其中一层材料是可拉伸 和弹性的,而第二层是可拉伸但无需有弹性。在对这 种叠层材料拉伸时,其第二层材料至少被永久拉抻到 一定程度。在本发明的一个特别优选的方案中,被增 量拉伸的叠层坯料的相对周边部分是受到抑制(固 定)的。

Description

本发明是关于一种在基本未拉伸的条件下组装并可用机械拉伸获得弹性的“零应变”拉伸叠层坯料的。
进一步说,本发明是关于生产可用机械拉伸在坯料的预定部分获得弹性的这样一种“零应变”拉伸叠层坯料的方法和装置的。
在本发明一特别优选的方案中,还说明了在“零应变”拉伸叠层坯料正沿机器方向(纵向)高速连续运动的情况下使这种坯料的预定部分在一个或几个方向获得弹性的方法和装置。
本发明还说明了包含有如一次使用尿布之类的多重吸附物的这种“零应变”拉伸叠层坯料。尿布一个接一个沿腰带部分相连,每一尿布还至少包括一被固定到顶层、后层或顶、后两层的弹性件。而该弹性件处于一基本未拉伸状态,故至少有包含有该基本未拉伸的弹性件的一部分受到机械拉伸并使这机械拉伸足以使固定有该弹性件的坯料产生永久性拉长。在没有对弹性件固定的情况下,当将拉伸力放松和弹性件返回到它基本未拉伸结构时,这被永久拉长了的坯料就会在垂直于弹性件平面的方向,于弹性件两邻的固定点之间受到Z方向的松散。无论Z方向的松散(蓬松)程度如何,坯料的“零应变”拉伸部分便会此后在初始的拉伸方向,至少在起始拉伸点的范围内是可弹性拉伸的。
在一特别优选的方案中,本发明还进一步介绍了叠层坯料的机械拉伸是使它通过一对啮合的波纹辊来进行的。
在本发明一特别优选的方案中还说明了一种如尿布之类的一次使用的吸附绷带结构,这种结构具有用本发明的方法和装置生产的独立的弹性部分。
正如和这里所使用的那些术语一样,用最简单的话来说,所谓“零应变”拉伸叠层坯料是指至少包括有两层彼此相连的材料的坯料,其中的彼此相连是指在基本未拉伸(“零应变”)状态沿共同延伸表面的至少一部分间断地或基本连续的方式进行的。最好是有至少一层材料是呈连续坯料的形式以便于进行连续高速的加工。其它层可包括一连续坯料或以预定位置固定到这连续坯料上的一些独立件或垫。
如上所述,“间断地”粘结的叠层坯料将意味着一种是在未施加拉伸之前就首先将两层材料以一些彼此隔开的点粘结起来的叠层坯料,或是各层在各个隔开的点彼此基本上是未粘结起来的叠层坯料。第一种间断粘结的叠层坯料可使两层可热粘结的材料通过一加热分布压印辊隙来形成,或者在使两层接触之前对其中一层加上一些彼此隔开的粘结区来形成。而第二种间断联结的叠层坯料可在两层完全连续材料层之间放进一层涂有粘结涂料多孔的材料或沙罩来形成。相反,“基本连续”粘结的叠层坯料将意味着,叠层坯料是在未加拉伸前首先沿其整个接触面彼此完全(基本)粘结起来的。基本连续粘结的叠层坯料可将第一基本连续、热塑粘结层在它处于热状态时,直接挤压到第二层,并使两层可进行热粘结的层通过一加热的表面光滑的辊隙来形成,或者可在使两层进行接触前,将一完全连续的粘结涂层,喷射液或稠密的成型吹熔体加到其中一层来完成。
本发明“零应变”拉伸叠层坯料使用的一层材料是由一可拉伸和有弹性的材料组成的,即它在放松加给的拉伸力后,会基本恢复到其未拉伸时的尺寸。固定到弹性层的第二层是可拉伸、最好是可拉拔但无须有弹性的材料。无论为什么样的构成,它的第二层在拉伸时至少要有一定程度的永久变形,使得在放松加给它的拉伸力时,它不会完全恢复到它原来没变形时的结构。从永久拉长的意义上说,第二层在拉伸工序后是不固定到弹性坯料上的,永久拉长了的第二层当固定的弹性坯料返回到它X-Y平面基本上不变形结构时,便在它的弹性坯料固定点之间的Z方向膨胀。拉伸后X-Y平面相邻固定点之间的距离越大,最后的叠层坯料在Z方向的膨胀程序就越大。无论Z方向的膨胀度多少,得到的“零应变”拉伸叠层坯料此后便会在起始拉伸的方向,至少在起始拉伸点的范围内是可弹性伸缩的。
所谓“零应变”一词,在这里是用来叙述与本发明有关的拉伸叠层坯料的。据本申请人所知,它并未被以前的技术工作者使用来描述上述类型的坯料,而为便于一致性,在全部说明中仍采用它来描述这种坯料。
一种很早就实现了的断续粘结“零应变”拉伸叠层坯料是于1937年3月30日授予Galligan等人的美国专利2075189中公开的。按照上述Galligan等人的专利,将其中一层是处于拉伸和经过纵向拉伸的两层叠层在一起的连续橡胶层通过一对以同一圆周速度运动的压力辊。其中一个辊具有按所要求的图形分布的相对小的窄的突起部分。这些突起部分与第二辊联合作用一起压到两层橡胶的粘性接触的细小部分,使这两层叠加起来的橡胶的相对紧密相间的细小区域按类似于压力辊突起部形成的图形被联结起来。
按照Galligan等人的专利,与具有突起部(图形)的辊相配合的辊可以是光滑的,或者可以是具有与其它辊相类似的匹配突起(图形)的。两辊是相隔开的,其相隔距离将取决于在不使橡胶的联结表面过薄的情况下,两层橡胶的组合厚度和足以产生联结压力的大小。
按照从压辊出来的连结层,拉伸层的拉伸是松弛的,因此这层长度减少,宽度稍为增加。因为未拉伸断续粘结的层不能这样收缩,所以它就从皱纹或波纹4的纵向被拉起。在Galligan等人专利的图1和图2所示的具体方案中,用标号1代表顶层或波纹层,而拉伸层或支承层则用标号2来表示。在两层已被压力联结起来的点上出现三条细的平行联结线。
在Galligan等人专利的方法的后面步骤中,上述断续粘结的合成材料包括两层波纹材料并且在横向(大体上平行于连结线3的方向)是经过极高拉伸的,这种拉伸足以使顶波纹层1拉伸至超过它的弹性极限。然而,所加的拉伸仍然处于底层或支承层2的弹性极限。
如有必要,横向拉伸可以达到这样高的点;使它等于未变形材料原始宽度的八倍。
图为顶层1被横向拉伸超过它的弹性极限,所以它的波纹4必须在横向永久变薄,使得当放松叠层的横向拉伸时,任何有波纹的材料的表面积当被铺平时将比支承层2相应部分的面积大得多。结果,当支承层2横向收缩时,顶层1上的波纹4将从横方向被拉起,而且因为它们的表面积比以前大得多,所以支承层的收缩效应引起波纹在联结线3之间呈现出非常不规则的变形的形式,即正如图5、图6和图7通常表示的,它引起合成材料在Z方向的松散。Galligan等人建议,所获得的“零应变”拉伸叠层坯料特别适用于浴衣、浴毯、裙和其它物品的制造。
另一种早已实现的被特别建议用作毛巾、擦拭材料和可膨胀服装的间断粘结的“零应变”拉伸叠层坯料是于1962年3月13日授予Harwood的美国专利3025199中公开的。Harwood特别提供了一种沙罩结构,它由在它们的相交点彼此粘结起来的线或丝2和3的相交线族组成,以形成一网状加强网络1。最好是将一对无纺纤维层4和5粘附到由相交线形成的加强网络1的两相对表面上。
然后对Harwood的叠层坯料结构进行一个方向或几个方向的拉伸工序以便将固定到加强网络1的相对表面的无纺带4,5进行永久膨胀。按照Harwood的建议,这可经适当的轧辊装置,通过横向(即横过机器的方向)拉伸叠层坯料来进行,或利用适当导向并配备有夹持坯料的边缘和对坯料边缘施加相反的拉伸力的传送链(即拉幅装置)来实现。如要对叠层坯料进行纵向拉伸,Harwood提出,这可利用相配合的低、高速辊副来进行。
在一特别优选的方案中,因为用来形成Harwood的网状加强网络1所用的线2,3是弹性的,所以只要将已加给叠层坯料的任何拉伸力除去,网络1便有要恢复到其预定的基本上没变形的结构的倾向。结果,Harwood专利图4横截面所示的永久膨胀的最外层4和5便在与弹性网络1的开口相重合的非粘结区6表现Z方向的松散。
最近实现的、由合成的聚合层组成的、计划用作一次性衣服的间断粘结和基本连续粘结的“零应变”拉伸叠层坯料是在共同转让的并于1978年8月15日授予Sisson的美国专利4107364和共同转让的并于1980年6月24日授予Sisson的美国专利4209563所公开。通过引证结合在此的共同转让的Sisson专利提出,其中发明的“零应变”拉伸叠层坯料特别适用于一次使用的衣服,因为与普通的衣料相比,它的成本相对地低。Sisson专利还说明,这种“零应变”拉伸叠层材料可以许多不同的形式进行制造,其中包括从适用于做内衣裤的极轻重量型,讲适用于做衣服腰带的较重型的叠层坯料。
在一优选方案中,Sisson的“零应变”拉伸叠层材料至少包括一层基本上由相对弹性的合成聚合丝组成的材料和至少一层基本上由可相对拉伸但相对非弹性的合成聚合丝组成。在一特别优选的方案中,两层彼此粘结一起形成一粘附叠层坯料。
正如早先指出的,Sisson发现了两种坯料的粘结结构:基本连续的粘结,如可经一加热光滑辊隙来完成的;在多个间隔点基本间断的粘结,如可经加热成形的压印辊隙来完成的粘结。
无论采用那一种粘结结构的叠层坯料此后都是用拉伸之类的机械方法加工的,最好是非常均匀的拉伸,然后至少在一个方向完全放松以在拉伸方向产生一低的弹性模量。如果是间断粘结的叠层坯料,它的可拉长但相对非弹性层是用拉伸工序进行永久拉长的。因此,当将加给的拉伸放松,它就会在将它固定到相对弹性层的间断粘结点之间被松散和粘结,即,它在Z方向被松散到一显著程度,以产生一种在起始拉伸方向,至少在起始拉伸的范围内可弹性拉伸的“零应变”拉伸叠层坯料。如果是基本连续粘结的叠层坯料,当放松叠层坯料的拉伸时,相对非弹性的永久拉长的聚合丝就不会缩回去。因此,当将叠层坯料拉伸放松时,就会使它们在很小的范围,即在相对弹性聚合丝的粘结点之间被闭合,松散和粘结。因为Z方向的松散在这种连续粘结的叠层坯料是较不明显的,所以后一种“零应变”拉伸叠层坯料在拉伸方向,至少在起始拉伸点的范围内也是可弹性拉伸的。
在上述共同转让的Sisson专利中都发现了许多采用连续或间断粘结结构的“零应变”拉伸叠层坯料的例子和生产这些坯料的方法。
Sisson的关于在一次使用穿着衣服物品中采用“零应变”拉伸叠层材料的建议已为后来这方面的工作者所接受。例如,1985年6月25日授予Ness的美国专利4525407就公开了一次性使用的尿布和外科长衫。这些尿布和长衫包括一种或几种“零应变”拉伸叠层合成材料,而这些合成材料是由间断地粘结到一未拉伸的而可拉伸较小的基体材料上的一种未拉伸弹性件组成的。所得的叠层材料是用拉伸获得弹性的。
Ness的图1-3说明了一种打算用于弹性绷带或包装带的简单的两层“零应变”拉伸叠层坯料。这种叠层坯料包括一非多孔弹性件10和一未拉伸非收缩基体12。基体12在拉伸前比弹性件较不容易拉伸并具有比弹性件小的弹性恢复。基体材料和弹性体材料是以规则或不规则图形分布的间隔点14间断地粘结在一起的。之后将这叠层坯料进行如图2箭头所示方向的拉伸。当将加给的拉伸力放松,弹性件10产生皱起,即产生如图3大体上所示的,永久拉长了的基体12在粘结点14之间的Z方向松散。象Galligan等人,Harwood和Sisson上述“零应变”拉伸叠层坯料一样,Ness所发现的最后叠层坯料此后便在起始拉伸方向,至少在起始拉伸点的范围内是可弹性拉伸的。
另一种弹性复合坯料方案30是在Ness的图5-8说明的。后者方案采用一种网状的具有横向股线22和纵向股线24的弹性件20。Ness的网状弹性件20一般看来类似于上述Harwood专利图1-4所发现的弹性网状加强件1。和Harwood一样,Ness也采用了一种具有比弹性件20较小伸长性而又比弹性件具有较小弹性恢复的第一基体材料28。此外,Ness还采用了一第二基体材料30。这种材料具有和基体28基本相同的物理性质并具有“夹层的”弹性件10。
Ness的基体材料28和30至少被固定到网状弹性件20的相对表面上,而弹性件是处于基本未拉伸状态的。如有必要,也可以通过网状弹性件的开口将基体28和30彼此粘结在一起。按照Ness的说明,当以后将这叠层坯料进行纵向拉伸时,基体28,30受到永久拉长并可能彼此层离,但它们仍然会在包含有网状件的横向或纵向股线的中间位置被非连续地粘结到网状弹性件20。一旦将坯料的拉伸放松,这网状弹性件20就会使这坯料恢复到网状弹性件20基本上未变形的结构,因此引起永久拉长的基体28,30在它们固定到弹性件的纵向股线22的相间点之间,在大体上垂直于拉伸方向的方向上,产生Z方向的松散。图9所示的Ness的最后的弹性复合坯料的横截面大体上类似于上述Harwood专利图4所示的“零应变”拉伸叠层坯料的横截面。
除了上述的“零应变”拉伸叠层坯料方案以外,Ness专利的图9-12公开了使用弹性复合材料以分别沿一次性尿布的相对侧边和端部提供可拉伸的腿箍部分136,137和可拉伸的腰带部分138和139。这种弹性复合材料可在生产中加进服装或绷带中去,如有必要,还可对它进行拉伸以获得起始拉伸方向上的随后弹性可拉伸性。按照Ness的说明,后一拉伸工序既可以由最终用户去完成也可由供应商在销售时进行或者可在生产时进行拉伸。
Ness的图14公开了一种拉伸叠层坯料的自动方法。其中的叠层坯料包括一热封到一对相对塑料坯料层214和216的一网状弹性带210。在这发现方案中,将包含有复合物的三层材料通过由一对光滑加热反转辊子224和226形成的辊隙,以将这网状弹性线(带)热封到两层坯料224和226上,以形成一热封的三层复合体228。然后,将这热封的复合体228送到由第二对反转辊230和232形成的辊隙。第二对反转辊可能要进行冷却以保证这热粘结是“固定的”。然后将从第二对反转辊230,232出来的复合坯料234送到第三对反转辊236,238的辊隙,第三反转辊的圆周速度比第二对反转辊的圆周速度快,以在这两对辊之间对复合坯料234进行减拔。
按照Ness的说明,这种减拔是对薄膜214,216进行拉伸并对以前通过网状弹性沙罩的孔在薄膜214和216之间形成的热封粘结进行破坏。按照Ness的说明,在纵向拉伸具有弹性带的复合材料也可以破坏纵向股线和薄膜之间的密封,而只留下粘结到坯料层214和216的横向股线。当拉伸的复合体244从第三对反转辊236,238出来时,纵向或机器方向的拉伸被放松,复合体244被送到卷绕装置246。卷绕装置以约等于第二对反转辊230和232的圆周速度转动。
如第一辊副230,232和第二辊副236,238,将拉伸加到远隔支承点来拉伸一叠层坯料时,虽然它是用来实现对基本上无弹性的坯料层214和216永久拉长的,但是,申请人已了解到,当沿着复合坯料234的无支承部分进行测量时,这样一种“零应变”拉伸叠层坯料拉伸的均匀性随第一辊副230,232和第二辊副236,238之间的距离增加而下降。对于所给定的第一和第二辊副之间的任何距离,这种不均匀性随着第二辊副236,238和第一辊副230,232之间的圆周速度差的增加,即复合坯料234受到拉伸的程度越大,就变得越明显。
申请人已进一步了解到,这些不均匀性问题可利用上述共同转让的Sisson专利提出的下面其中一项具体建议来避免,至少可减少。即,使这种“零应变”拉伸叠层坯料通过一个增量式拉伸系统来对它进行增量拉伸。这种增量拉伸系统可以是诸如由一对相互啮合的波纹辊之间形成的辊隙。这种相啮合的波纹辊具有一个基本上垂直于坯料的运动方向的回转轴线。拉伸时,这些啮合的波纹辊以相应于波纹宽度的多个相隔很近的位置支承着叠层坯料。这样就使相邻支承点之间的叠层坯料每一非支承部分产生非常均匀的增量拉伸,而不是象在只在坯料的最外端受到拉伸那样常常发生的高度局部拉伸。
Sisson关于使“零应变”拉伸叠层坯料通过一对波纹辊来对它进行增量拉伸使它产生弹性拉伸性的建议也至少为后来的有关工作者所接受。例如于1989年5月30日授予Sabee的美国专利4,834,741,该专利通过引证结合在本申请中。
象Ness一样,Sabee发现了一种如一次性尿布之类的一次使用服装,这些服装采用一“零应变”拉伸叠层坯料。而叠层材料包括有以它的相对腰带和腿箍部分固定在一对可拉伸件之间的未拉伸弹性件。Sabee图1所示的弹性件41被固定在尿布膜的腰带部分,而对可拉伸顶层坯料、可拉伸的后层坯料或对前后层坯料均处于非常松弛的状态。Sabee采用的粘结结构可以是间断的也可以是连续的,间断的如将叠层材料通过由两辊形成的压力辊隙,其中一辊被加热并在它的表面包含有许多凸起点;连续的则如:将一条薄的粘弹性热熔压力敏感粘结带置于其中一层坯料上,然后使这叠层通过一由一对光滑表面辊形成的压力辊隙,将这热熔压力敏感粘结剂压到另一层坯料上。
之后,无论采用那一种粘结结构,将包含有弹性坯料件41的尿布坯料部分利用波纹辊副31的啮合波纹在横过机器的方向进行横向拉伸,如Sabee的图5和图6所示。将弹性件固定区内的可拉拔顶层和后层坯料的重叠部分同时进行增量拉伸和拉拔以在横过机器方向(即横向)获得一永久拉长及其分子定向。因为波纹辊31有它们完全平行于机器方向(纵向)的啮合波纹,因此便会在横过机器方向(横向)发生膜的增量拉伸。因此,经过充分加工的Sabee尿布膜的腰带部分以后在横向,至少在开始拉伸点的范围内是可弹性拉伸的。
如图12和13所示,关于包含有未拉伸弹性件42的相对腿箍,其类似的纵向拉伸工序最好是将Sabee尿布坯料通过另一对啮合波纹辊89来进行。因为波纹辊89有它们大致平行于横过机器方向的啮合波纹,因此在机器方向发生坯料的增量拉伸。因此,Sabee尿布坯料的腿箍部此后在机器方向,至少在起始拉伸点的范围内是可弹性拉伸的。
虽然申请人已确认,Sisson关于采用波纹辊来增量拉伸一“零应变”、拉伸叠层坯料的建议,当膜的大部分或整个表面受于处理时,这一建议效果很好,但当仅处理这种坯料预定的孤立部分或坯料的预定部分仅包括一“零应变”拉伸叠层复合材料时,就会遇到一些不希望有的问题。例如,上述Sabee专利图5,6,12和13所示的尿布坯料只有腰带和腿箍部是由“零应变”拉伸叠层坯料组成时,这尿布坯料的“零应变部分”就会在平行于如它们通过啮合波纹辊进行拉伸时所要求的方向有明显的滑移或收缩的倾向。
叠层坯料的“零应变”部分在平行于拉伸时所要求的方向滑移或收缩便降低了增量拉伸方向的效果。在这种情况下,粘结弹性件的相对非弹性层就不会受到象如果不允许叠层坯料在平行于坯料拉伸方向的方向受到总收缩的情况那样大的拉伸程度。结果,最后的“零应变”拉伸叠层坯料的激活或拉伸的部分,当将成品从坯料切下或进行使用或由使用者穿用时,就显出较小的收紧度和较差的弹性拉伸性。
当包含在膜内的各个弹性件的尺寸或被增量拉伸的拉伸叠层坯料的部分越来越小时,上述问题就会变得越来越严重。
因此,本发明的目的之一是为增量拉伸“零应变”叠层坯料提供改进的方法和装置,以此来最大地提高增量拉伸方法的效果。
在本发明一个特别优选的方案中,其进一步目的是提供为对“零应变”拉伸叠层坯料的相对周边部分进行限制,以防止当该叠层坯料进行增量拉伸中间的这些抑制点时,在平行于拉伸方向的方向产生滑移或收缩的这样一种方法和装置。
本发明的另一目的是提供高效的方法和装置,在一特别优选的方案中,利用这种方法和装置可很容易在连续运动的“零应变”拉伸叠层坯料内生产出细小,独立的弹性区。
本发明包括增量拉伸一“零应变”拉伸叠层坯料,以在开始拉伸的方向,至少在开始拉伸点的范围内产生它的弹性的改进方法和装置。虽然“零应变”拉伸叠层坯料本身在使用啮合波纹辊来增量拉伸这种“零应变”拉伸叠层坯料以获得它的弹性的技术中是众所周知的,但本发明的申请人业已发现,这种包含有基本未拉伸的弹性件的叠层坯料的“零应变”部分,在平行于坯料通过啮合的波纹辊被增量拉伸时所要求的拉伸方向的方向会有明显的向内滑移或收缩的倾向。申请人还进一步了解到,这种向内滑移或收缩降低了增量拉伸方法的效果,因为间断或基本连续连结弹性件的,相对无弹性可拉伸的坯料不会受到象不允许叠层坯料在平行坯料拉伸方向的方向上受到这种向内滑移或收缩的情况下那样大的拉伸率。
本发明的申请人通过提出在进行增量拉伸时至少对。“零应变”拉伸叠层坯料的非弹性可拉伸坯料部分的相对周边进行限制的方法和装置,解决了上述问题。在一优选方案中,“零应变”拉伸叠层坯料在进行增量拉伸过程中也是被抑制的。
在一特别优选的方案中,当坯料通过一对具有波纹并彼此有一定的啮合度的波纹辊时,“零应变”拉伸叠层坯料的相对周边部分是通过对坯料施加真空或施加夹紧力来进行限制的。
虽然以权利要求书为结尾的说明书已特别地指出和明确地规定了形成本发明的主题,但相信,通过参考下面各图的具体说明将会对本发明有更好的理解。其中:
图1是说明装配一次性尿布坯料的简化透视图。每一尿布沿其长度都有固定在规则的间隔位置上的弹性垫。其中,坯料在与弹性垫重合的区域正受到采用啮合波纹辊的增量拉伸,此外,坯料正沿其长度在预定点被切断以形成多重的一次使用的尿布,每个尿布至少有一对可横向拉长的侧条。
图2是本发明一特别优选方案的简化透视图,该方案采用了一真空坯限制系统。
图2A是沿图2线2A-2A所取的简化视图,说明采用惰辊来使尿布坯料绕到最下面的波纹辊的方式。
图2B是图2中2B处的局部放大视图,它说明当尿布坯料的“零应变”拉伸叠层部分通过波纹辊之间时波纹辊的啮合程度的。
图3和图4是说明在进行本发明的增量拉伸方法时可采用的本发明的可供选择的坯料限制系统和简化透视图。
图3A是图3的3A处沿连结最上波纹辊25和最下面波纹辊21的中心线所取的截面简化放大视图。
图4A是图4中4A处沿连结最上面波纹辊25和最下面波纹辊21中心线的截面放大视图。
图4B是坯料通过图4A所示类型波纹辊隙后,本发明的间断粘结的“零应变”拉伸叠层坯料的放大截面视图。
图4C是膜通过4A所示类型波纹辊隙后,本发明的基本连续粘结的“零应变”拉伸叠层坯料的截面放大视图。
图5是本发明的另外一种增量坯料拉伸系统的示意图。
对熟悉有关技术的人是不难明白的:虽然本发明的下面叙述只与具有预选弹性区的一次使用尿布结构有关,但本发明几乎对任何连续运动的坯料都可以很方便和高速地使用,无论是全部由“零应变”拉伸叠层坯料组成的膜或是包括有独立、分开的“零应变”拉伸叠层坯料部分的坯料。
尿布的制造方法和尿布虽然在各附图中仅作了原理性说明,但如需要,它一般可类似于1978年3月28日授予Buell的共同转让的美国专利4081301所公开的尿布制造方法和尿布,该专利通过引证结合在本申请中。但是,Buell尿布的弹性腿箍是随意选择的,并没有清楚说明。图1-4A图示的尿布坯料和沙漏型尿布在一组或两组沙漏的吊耳部分采用了弹性侧条。在至少一对吊耳中设置可用来生产这种弹性侧条的这种分离的弹性件,基本被1989年8月5日授予Wood等人的美国专利4857067号公开,该专利也通过引证结合在本申请中。
参考图1,它示出了由多个互连着的一次使用的尿布2组成的连续坯料1。每一尿布由一吸附垫件3、一对弹性件或贴片4a、一不透水的后层材料5和一透水的顶层材料6组成。弹性件或贴片4a可以由以预定的相间位置固定到坯料上的“生的”合成或天然橡胶、合成或天然的橡胶泡沫、弹性薄膜、弹性无纺叠层材料,弹性沙罩或其它类似的材料所组成。吸附垫和弹性贴片是被放置在不透水的后层材料5与透水的顶层材料6中间。不透水后层材料5在一般的情况下是由如一密耳原的聚乙烯薄膜之类的可拉伸的聚合材料组成的。而透水的顶层材料6在一般情况下是由可拉伸的无纺纤维材料或可拉伸的多孔聚合薄膜组成的。
可用作弹性件或贴片4a的特别可取的材料包括至少具有约400%的断裂拉伸率和在它未应变长度的50%拉伸情况下每英寸样品宽度具有大约200克的拉伸力的泡沫。已发现可使用的典型的泡沫是:可从新泽西州的帕拉姆通用泡沫公司(General Foam of paramus,New Jersey)买到的,号码为40310的通用泡沫公司的聚胺脂泡沫,这种泡沫具有一个空载厚度或约为80密耳的厚度,每立方英尺的密度约为2.06磅(约0.033克/cm3);桥石(Bridgestone)SG聚胺脂泡沫,可从日本的Yokohama桥石公司可买到的,这种泡沫有一空载厚度或约80密耳的厚度,其密度约为2.06磅/英尺3(0.033克/厘米3);交叉耦连(Cross-linked)天然橡胶泡沫,它有一空载厚度或约50密耳的厚度,密度约为13.3磅/英尺3(0.214克/厘米3),可从美国罗得岛的Middlefon Fulflex有限公司买到;以及交叉耦连的天然橡胶泡沫,它有一空载厚度或约50密耳的厚度,密度约为13.3磅/英尺3(0.214克/厘米3),它可从俄亥俄州的Fremont的鲁得罗(Ludlow)公司买到。
对后层5特别好的材料是包括有由45-90%的线性低密度的聚乙烯和10-55%聚丙烯的混合物。如果以非压印的形式使用,在一般的情况下,后层材料5具有一个空载厚度或约1密耳的厚度。如必要,可以将后层压印到约为5.5密耳的厚度以增强坯料的处理和外观特性。已发现被使用的一般后层材料是:可从印地安州的Terre  Haute的Tredegar工业有限公司买到的RR8220混合物REDEM和RR5475的混合物ULAB。
一种特别适用于做透水顶层6的材料是一种疏水性无纺普梳坯料,这种普梳坯料的基本重量约为18-20克/码2,由约2.2丹尼尔的聚丙烯纤维组成,它可以代号P8从马萨诸塞州的Walpole的国际纸品公司的一个部(Division of International Paper Co.),Veratee有限公司买到。
当后层5,顶层6或这两层由弹性的三维聚合坯料组成时,会使尿布坯料的“零应变”拉伸叠层部分获得特别可取的美丽外观。这种聚合坯料在于1982年8月3日授予Radel和Thompson的并已共同转让的美国专利4342314中基本公开。因此该专利通过引证结合在此。
后层材料5和顶层材料6的连续坯料最好在机器方向(即纵向)保持很小的拉伸(本质上是“零应变”),以防止起皱,并易于与尿布体(diaper  assembly)相配合和进行有关转换工序直到将完成的尿布坯料用切刀22切成各个尿布2为止。
尿布坯料的形成工序仅在图1以图解方式作了说明。吸垫部分3以规则相间的预定间隔被送到由一对组合辊或积层辊15形成的辊隙。在一特别优选的方案中,吸垫件3最好是由被限制在一纤维织物封套内的气毡组成,以保证吸垫在使用时的整体性。
正如早先已指出的,本发明的“零应变”拉伸叠层坯料即可采用间断的粘结结构也可用基本连续的粘结结构来生产。通常,间断粘结结构在下述这些情况下是可取的;即叠层材料中基本无弹性的坯料是可相对拉伸或可拉拔而无断裂的,以及完成的叠层材料要求在Z方向的松散程度很高的。
而对连续粘结结构则与此相反,它通常在其Z方向的松散度是无关重要的,并且叠层材料中的一层或几层相对无弹性的坯料在不产生断裂的情况下是难以拉伸或拉拔的这些情况下才发现是可取的。在后者情况下,基本连续粘结结构在进行增量拉伸工序后将使叠层的所有层彼此具有相对紧密的粘连。因此,在进行增量拉伸工序时即使有一层或一层以上相对无弹性坯料被损坏到破裂点,但由于相对无弹性坯料的损坏部分与弹性层之间的相对紧密的粘结使最终用户很难觉察出有任何损坏。如果相对无弹性坯料的断裂不影响坯料所要求的功能,例如不透水性,在增量拉伸工序时对相对无弹性坯料产生的损坏作为最终产品的一个缺陷是觉察不出来的。
这样,在本发明特别优选的“零应变”拉伸叠层坯料中从使用连续粘结结构获得的一个意外效益是:它允许弹性件的生产者可以从可能在本发明的叠层材料被成功地使用的更大范围的相对无弹性坯料材料中进行选择。主要的,它允许采用相对无弹性坯料,而这些坯料在本发明的“零应变”拉伸叠层坯料中通常都不认为能拉伸到任何明显程度的。因此,在本说明书和权利要求书中使用的“可拉伸”一词,除非清楚地说明,它都不意味着排除在增量拉伸工序中会受到一定程度变薄或损坏的相对无弹性坯料。
正如在图1方案中可看到的,不透水可拉长后层材料的连续坯料是直接接近涂胶器10的。如果为在成品的Z方向获得最大程度的蓬松(松散)而要求采用间断粘结的叠层坯料,则可利用涂胶器10在将要在其上放置完全未拉伸的弹性垫4a的后层材料5的那些预定位置上,施加分离的、隔开的粘结剂。
在另外一种情况下,如果要求采用基本连续粘结的叠层坯料,则可采用涂胶器10在要放置基本未拉伸的弹性垫4a的那些预定区域上,将一基本均匀和连续施放的粘结剂10a加到后层材料5上。在后一种一个特别优选的方案中,选用的粘结剂是可延伸的,涂胶器10包括有一热熔吹施装置(melt  blown  application  system)。
申请人发现了特别适用于生产本发明的基本连续粘结的“零应变”拉伸叠层坯料的这样一种垫熔粘结剂吹施系统是型号为GM-50-2-1-GH热熔体吹喷器,它可从Georgia(乔治亚)州的Gainesville J & M实验室买到。后一系统采用一个每英寸长有20个孔的喷嘴,当沿其横过机器方向测量时,它每孔的直径约为0.02英寸。可从俄亥州(OChio)Findley Adhesives(快得利粘结剂公司)买到的Findley H-2176热熔粘结剂,最好是将它加热到约340°F的温度并以每平方英寸7.5-10毫克的比率将其加到后层材料5上。在进行施加粘结剂时,通过粘结剂喷嘴的第二孔送出温度约为425°F,压力约为50磅/英寸2的热压缩空气。
如图1中10a大体上所表示的热胶与后层坯料5在对尿布坯料的最后“零应变”拉伸叠层部分进行增量拉伸之前的紧密接触可软化后层材料5。对于某些坯料,例如普通的聚乙烯后层材料,业已发现,这种软化对减少在进行坯料的增量拉伸工序期间后层材料的破坏有帮助。这在使有关坯料所生产的成品获得某些功能,例如不透水功能的情况下是特别重要的。
在另外一种情况下,包含尿布坯料的“零应变”部分的部件可采用不加热的粘结剂、热粘结、压力粘结、超声粘结等间断地或连续地粘结起来。在这些情况下,如果必要,可以利用有关人们熟悉的其它装置,例如辐射加热器(未画出),热吹风机(未示出)等将热能加到后层材料5,均可达到相同的效果。
两卷弹性材料4以一定的速度和很小的拉伸(本质上是“零应变”)送到砧辊11上。在这个一定的速度下,每块尿布获得要求长度的弹性垫4a。辊11在它的周边配备有真空压吸孔(未示出)。切刀12给每个尿布作一次切割,基本未拉伸的弹性垫4a被真空固定到砧辊11周边并随它一起运动直至它们达到传送点13。在点13,这些弹性垫4a最好用高压鼓风机将其传送到与粘结剂10a重合的后层材料5的预定部分。这种传送是顺序的。备有真空的砧辊11和后层材料5的表面速度基本上是相同的。
然后使具有被沿其长度固定到它的预定点的弹性垫4a的后层材料5通过一对叠层或组合辊15。
使诸如可拉伸纤维无纺坯料之类的透水顶层材料6的连续坯料靠近第二涂胶器14。这涂胶器最好能施加一按图形分布的、尺寸和位置又完全与后层材料5的弹性垫4a的尺寸和位置相匹配的粘结剂14a。正如后层材料5,加到顶层材料6的按图形分布的粘结剂,根据顶层材料6的性质和最后的“零应变”拉伸叠层坯料所要求的特性,它即可以是间断的也可以是基本连续的。如必要,涂胶器14可以与涂胶器10相同。
使后层材料5,顶层材料6和吸垫3在组合辊15互相接触。最好刚好在坯料和垫彼此接触之前利用装置(为了简洁,此装置未在图1示出)对一坯料或两坯料加些额外的粘结剂。这后一粘结剂将后层、顶层和吸垫的预定部分彼此固定起来以形成尿布坯料1。
之后最好使完全组成好的尿布坯料1继续通过一对粘结固定辊16,这可能要求冷却以减少粘胶渗出。
然后使完全组装好的尿布1通过本发明的增量坯料拉伸系统。这系统在图1中仅以一个方块20来表示。可作为系统20使用的本发明的一个特别优选的增量坯料拉伸系统的具体细节是在图2表示的。
参考图2,包含有基本未拉伸的弹性垫4a的尿布坯料的定时是这样的:当尿布坯料1从最上面的波纹辊15的扇形块24和具有连续波纹或槽的最下面的波纹辊21之间通过时,包含在尿布坯料内的基本未拉伸的弹性垫4a就完全与波纹或有槽的扇形块24重合。如必要,有槽的扇形块24当沿机器方向测量时可以有比弹性垫4a大的总长度,以使在完成的尿布中,在与弹性垫4a相邻的那些顶层和后层部分有一定的拉伸性。
因为最上面和最下面的波纹辊的互补槽的具体结构、间距和深度是根据诸如已完全加工好的坯料的“零应变”拉伸叠层部分所要求的弹性量之类的因素而变化的,因此,在本发明的一个特别优选的方案中采用的峰至峰的槽距约为0.15英寸,在峰部测量的夹角约为12°,峰至谷的槽深约为0.3英寸。上述波纹辊的每一波纹的外峰在典型的情况下具有约为0.01英寸的半径,而相邻波纹之间形成的内槽在典型情况下具有约0.04英寸的半径。当调整波纹辊使它们的相对峰彼此搭接到0.15到0.175英寸之间的深度时,便已能在本发明的叠层坯料获得良好的弹性特性。本发明的叠层坯料由80密耳厚的弹性聚胺酯泡沫垫4a和1密耳厚的不透水聚合后层材料5以及一疏水无纺顶层材料6组成,其中的泡沫垫4a被完全连续粘结到顶、后层材料的相对表面上,顶层材料6的基本重量为18-20克/码2并包含有大约2.2丹尼尔的聚丙烯纤维。
当然,上述波纹辊相对峰的搭接程度是可以按要求调整的,以便使坯料的最后“零应变”拉伸叠层部分产生或多或少的拉伸率。对于上述辊的几何形状和叠层坯料结构来说,其峰至峰的搭接深度从小至0.05英寸到大至0.225英寸都是可以的。
如可从图2A看到的,尿布坯料1是由惰辊72、74将它卷绕到最下面的波纹辊21以完全将作用真空孔22复盖住。这真空孔22是直接做在最下面辊21与每组槽23相邻的位置上。真空孔22被定位到使其完全与最上面的波纹辊25的有槽扇形块24相重合,它是通过辊21被内联到一对真空岐管26的。真空岐管26用来当尿布坯料被最上面的波纹辊25的有槽扇形块24作用时,对尿布坯料进行吸附的。
为了减少用来将未拉伸的弹性垫4a固定到透水顶层坯料6和不透水后层材料5的粘结剂或者是用来粘结顶层材料和后层材料的彼此重叠部分的粘结剂的聚积,最上面辊25的有槽扇形块24和最下面辊21的连续槽23最好是用如特氟隆(Teflon)之类的低摩擦材料或涂有如503号的Permalon喷涂料之类的材料组成,后者可从依利诺斯州(Illinois)的Morris的微表面公司(Micro  Surface)买到。
最下面辊21的真空孔22最好用如0.090英寸目的蜂窝结构之类的多孔材料44复盖住,以对被真空作用的尿布坯料1的部分提供支承和对坯料提供良好的固定表面,无论坯料什么时候被真空作用,均可完全防止坯料在蜂窝表面产生横向滑移或运动。
在最佳情况下,可给包含有弹性垫4a的尿布坯料1的“零应变”部分生产最大程度增量拉伸的是由最上面波纹辊25的扇形块24上的槽和最下面波纹辊21上的连续波纹23之间的啮合深度决定的。然而,申请人已发现,除非拉伸的叠层坯料在它通过啮合的波纹辊时,可完全防止它在完全平行于坯料拉伸方向的滑移或收缩,否则增量拉伸的最佳程度是不能实现的。所以,本发明的增量坯料拉伸工序是以它的最佳形式进行的,因为正如图2B的横截面大概地表示的,组成“零应变”拉伸叠层复合材料的所有三层的最外面部分是受到控制的,因此当尿布坯料的“零应变”拉伸叠层部分通过顺序啮合的波纹辊时,就完全防止了它在平行于拉伸所要求的方向生产滑移或收缩。
但是,本发明也可通过仅限制复层坯料的可拉伸或可拉拔层,即,在并不绝对要求弹性垫4a的最外面部分也要在增量拉伸工序中进行控制的情况下,加以有利地利用。在后者情况下,可拉伸或可拉拔层在进行增量拉伸工序时仍然被永久拉长,但最后的“零应变”拉伸叠层坯料Z方向的蓬松在除去拉伸的张力时,可能有点不明显。这是由于弹性层在这工序中受到较小程度的初始拉伸这一事实造成的。因此当它回到它的未变形结构时它只能受到同样量的回缩。
上述类型的“零应变”拉伸叠层方案在可拉伸坯料或在紧挨着弹性件4a的相对边区域的坯料也可能表现一定程度的不成比例的应变。如果是通常过用作不透水层的不透明聚合后层材料,这些不成比例应变的部分可能会变得很薄以至使它们可能出现透明,尽管它们没有发生断裂现象。在这种情况下,尿布坯料的“零应变”拉伸叠层部分的功能性,例如它的不透水性便不可能获得。后种类型的方案通常使用在下述情况:即从产品的设计或结构观点,最后成品的“零应变”拉伸叠层部分的美丽外观是看不到的,或者即是能看到也是产品的使用者不关心的这些情况。
还有本发明的另一方案,在这一方案中,即使有一层或一层以上的可拉长的非弹性坯料已破裂,也不会使最后的“零应变”拉伸叠层坯料失去它的预定用途。例如,后层材料5的破裂也不会破坏这种叠层坯料预定用途的功能性,而只要叠层坯料的其它层仍能提供成品中所要求的功能。例如,如果弹性垫4a是由一不透水材料组成的,则可拉长的后层坯料5有些破裂也不会破坯所获得的一次性使用的尿布坯料的不透水性。这对有关层之间采用完全连续粘结方法的那些“零应变”拉伸叠层坯料来说,更是如此。这些坯料层在经过增量拉伸之后彼此之间的相对紧密的粘结使这些层的破裂很难被产品的最终使用者发现。
因为图1-2B所示的尿布坯料1由于有最上面的不透水的后层材料5,而完全不透气,因此,必要时,可在直接相邻于最下面波纹辊21的沿机器方向取向的每组槽23采用被多孔蜂窝结构材料44复盖的真空孔22。如果弹性垫4a是完全透气的,则由真空产生的吸力将通过透水顶层坯料6和弹性垫,以牢牢地吸住后层5的叠加部分。在这种情况下,组成尿布坯料的“零应变”拉伸叠层部分的所有三层将在增量拉伸期间被抑制住。
如果弹性垫4a不是完全透气的,则需要(a)将真空孔22和叠加的蜂窝材料44刚好定位在弹性垫4a的相对边的外面,使吸力能通过透水可拉长的顶层6作用在不透水的可拉拔的后层材料5上;或者(b)利用能够对尿布坯料1的相对表面作用的压紧装置将组成尿布坯料的“零应变”拉伸叠层部分的所有三层抑制住。这些装置将随后介绍。
利用通过多孔蜂窝结构材料44作用的真空孔22将吸力加到图1-2B所示的尿布坯料1完全防止了带有完全未拉伸的弹性垫4a的尿布坯料的那些部分当它们通过最下面波纹辊21的连续槽23和最上面波纹辊25的有槽扇形块24之间的啮合部分时,产生横向向内滑移或收缩。
由于包含有弹性垫4a的尿布坯料1的“零应变”拉伸叠层部分在后面的整个坯料的拉伸工序中均被横向抑制住,所以位于中间最外面抑制点的“零应变”拉伸叠层坯料的所有部分,当这坯料在最下面波纹辊21的连续槽23和最上面波纹辊25的有槽扇形块24的啮合部分之间通过时,便受到非常一致的增量拉伸。
通过将固定有弹性垫4a的可拉长顶层和后层材料在进行拉伸工序时使它们强迫受到最充分可能的拉伸程度,不仅能提高增量坯料拉伸的效果,而且完全防止了被固定在弹性垫的相对周边部分附近区域的顶层和后层坯料不一致的高度应变。
图3揭示了可用作图1所示的系统20的另外一种本发明的增量坯料拉伸系统。在图3所示的增量坯料拉伸系统中,在紧挨着最上面波纹辊25的有槽扇形块的每边安装了一对可弹性压缩盘40。如图3A大致上所示,可压缩盘40具有足够大的直径,使它们能够紧紧地压住尿布坯料1并可靠地将它保持在最下面波纹辊21与盘相重叠的无槽部分上。象图2方案中的真空孔22和多孔蜂窝结构材料44一样,压缩盘40和最下面辊21的重合的无槽部分联合产生的压紧效果,完全防止了当坯料通过啮合的波纹辊时,在平行于拉伸方向的方向上产生收缩。本发明的图3方案可同样有效地用于由透气或不透气坯料组成的叠层结构。
图4还揭示了可用作图1所示的系统20的本发明的另一种增量坯料拉伸系统。在图4方案中,图2方案的真空孔22和图3方案的压缩盘40用一对连续的皮带50代替。这对皮带50以与最下面波纹辊21相同的圆周速度绕惰辊72、74、76和78运动并保持一定的拉伸度,以防止当包含有弹性垫4a的那部分尿布坯料1从最上面波纹辊25的有槽扇形块24和最下面波纹辊21的连续槽23之间通过时发生横向运动。图4A的横截面图揭示了由皮带50对尿布坯料1的“零应变”拉伸叠层部分产生的压紧作用。本发明的图4方案也同样可方便地用于由透气或不透气坯料组成的叠层结构。
图4B的横截面揭示了一种本发明的未拉伸间断粘结的“零应变”拉伸叠层坯料的状态,是作为在相当于它最大程度的增量拉伸点看到的。而图4C的横截面揭示的是本发明的另外一种同样未拉伸的完全连续粘结的“零应变”拉伸叠层坯料的情况,也是作为在相应于它的最大程度增量拉伸点所看到的。虽然这两种坯料在起始拉伸的方向,至少在起始拉伸点的范围内是可弹性拉伸的,但图4B所示的间断粘结的“零应变”拉伸叠层坯料呈现出大得多的Z方向蓬松程度。
正如熟悉有关技术的人们所知道的,上述抑制方案既可单独使用也可联合使用以获得最后尿布坯料1的最后“零应变”拉伸叠层部分所要求的益处。
在图1中20所图示的增量拉伸工序之后最好是让完全组合好的尿布坯料1通过60所示的侧切口装置,其中预想的与穿着者的腿相一致的缺口是从完全组装好的尿布坯料的横边缘部分切出的。
最后,将尿布坯料1沿其长度的预定位置用刀22切下以生产出水漏型(hourglass-shaped)的一次使用的尿布。这种尿布至少有一对在完全平行于尿布腰带的方向至少在起始拉伸点的范围内是可弹性拉伸的侧条。
从包括在这里的叙述,很清楚,对生产各种完全由“零应变”拉伸叠层坯料部分组成的或是仅包括一、两分开、独立的“零应变”拉伸叠层坯料部分组成的弹性物品都可有利地利用本发明的改进方法及其装置。
人们也认识到,虽然在附图中表示的是一对具有它们完全彼此平行对准的波纹的啮合的波纹辊,但本发明同样可方便地使用一对其波纹不是完全彼此平行取向的波纹辊。而且,这样一对波纹辊的波纹并不需要沿机器方向或横机器方向平行对准。例如,如果要求用这里所说的“零应变”拉伸叠层技术构造的,具有曲线腰带或腿箍部分的一次使用的尿布,用来增量拉伸尿布的“零应变”部分的这对波纹辊的啮合齿可按要求的曲线结构排列,以产生出沿要求的曲线轮廓而不是按直线的弹性。
还进一步认识到,虽然这里发现的优选方法是采用啮合的圆柱波纹辊,但对使用本发明极为重要的有关坯料的限制原理也可利用间断冲压工序来实现,这种冲压工序系采用啮合的压板来增量拉伸有关坯料或物品的“零应变”拉伸叠层部分。在后者情况下,唯一的要求是,对要进行增量拉伸的“零应变”拉伸叠层坯料,在啮合压板能够对坯料施加足够的力引起在平行于拉伸方向的方向滑移或收缩之前,要利用适当的其它装置或压紧装置将它充分抑制住。
这样一种间断冲压工序如图5所示。其中的尿布坯料101包括一透水的顶层6,不透水的后层5,吸垫3和完全未拉伸的弹性垫110和120。弹性垫110和120分别形成尿布坯料的“零应变”拉伸叠层腰带部分210和曲线“零应变”拉伸叠层腿箍部分220。
使尿布坯料从一对啮合压板之间通过。底压板440的曲线齿520用于增量拉伸尿布坯料的腿箍部分,直齿510用来增量拉伸尿布坯料的腰带部分。尿布坯料101被下压板440支承。上压板400具有与下压板440的有齿部分互补的有齿部分并与下压板相啮合。
为了保证达到最大程度的增量坯料拉伸,下压板440的有齿扇形块510,520最好是用可变形的弹性窗口610,620包围起来,这些可变形窗口以它们的周围对着相应一组不变形的并包围着上压板400的互补齿的窗710,720,与尿布坯料101的“零应变”拉伸叠层部分210,220接触并将它们压紧。这种压紧作用防止了坯料的“零应变”拉伸叠层部分在这套啮合压板上进行增量拉伸工序时在大致平行于拉伸方向的方向收缩。当然,可弹性变形的窗口610,620必须充分变形以适合进行增量拉伸工序时压板400和440的相对齿要求的啮合度。
在另外一种情况下,这些要增量拉伸的尿布坯料的“零应变”拉伸叠层部分210,220,在上啮合压板400能对尿布坯料的“零应变”拉伸叠层部分作用足够的力,以引起它们在平行于拉伸方向的方向收缩之前,能利用围绕着下压板440的有齿扇形块510,520的适当的真空装置(未示出)而被抑制住。
虽然本发明以在一次性使用尿布坯料上提供弹性吊耳或弹性腰带和/或腿箍为内容对它作了基本叙述,但可认识到,本发明在许多其它应用和环境也可加以有利使用。对熟知有关技术的人很明显,可在不脱离本发明的精神和范围的情况下进行各种变化和修改,因此打算在附加的权利要求书中包括属于本发明范围的所有修改。

Claims (33)

1、一种对零应变拉伸叠层坯料进行增量拉伸以使其在拉伸方向,至少在起始拉伸点的范围内获得弹性的改进方法,该方法的特征在于它包括下列步骤:
(a)将一零应变拉伸叠层坯料送入一对具有三维表面的相对的施压器之间,施压器的三维表面彼此有一定程度的互补性,零应变拉伸叠层坯料包括一基本未拉伸的第一弹性层,而第一弹性层被间断地固定到一基本未拉伸的第二层,这第二层是可拉伸的但比第一层具有较小的弹性;
(b)将邻接于要进行增量拉伸的零应变拉伸叠层坯料的第二可拉伸层的周边部分限制住,以完全避免在大致平行于拉伸方向的方向产生滑移或收缩;
(c)对位于相对抑制点之间的那部分零应变拉伸叠层坯料进行增量拉伸,而第二可拉伸层通过使施压器的相对的三维表面彼此至少有一定程度的啮合而受到抑制,因此使这第二可拉伸层被增量拉伸永久拉伸,使得该叠层坯料一旦将起始增量拉伸力从它上面除去时,便在起始拉伸的方向,至少在起始拉伸点的范围内是可弹性拉伸的。
2、一种增量拉伸零应变拉伸叠层坯料,以使它在拉伸的方向,至少在起始拉伸点的范围内产生弹性的改进方法,该方法特征在于包括如下步骤,
(a)将一零应变拉伸叠层坯料送入一对具有三维表面的相对的施压器之间,施压器的表面彼此有一定程度的互补性,零应变拉伸叠层坯料包括一基本未拉伸的第一弹性层,这第一弹性层被基本连续地固定到一基本未拉伸的第二层,这第二层是可拉伸的但比第一层具有较小的弹性恢复;
(b)将邻接于要进行增量拉伸的零应变拉伸叠层坯料的第二可拉伸层的周边部分抑制住,以完全防止在大致平行于拉伸方向的方向产生滑移或收缩;
(c)对位于相对抑制点之间的那部分零应变拉伸叠层坯料进行增量拉伸,而第二可拉伸层通过使施压器的相对的三维表面彼此至少一定程度的啮合而受到抑制,因此使这第二可拉伸层被增量拉伸永久拉伸,使得该叠层坯料一旦将它的起始增量拉伸力除去时,便在起始拉伸的方向,至少在起始拉伸点的范围内是可弹性拉伸的。
3、如权利要求1或2所述的方法,其特征在于第一弹性层的相对周边部分也是被抑制住的,以完全防止其零应变拉伸叠层坯料在其整个增量拉伸中,在平行于拉伸方向的方向上产生滑移或收缩。
4、如权利要求1或2所述的方法,其特征在于其相对的施压器包括具有完全垂直于坯料的运动方向的回转轴线的波纹辊,和其施压器的三维表面包括有波纹,这些波纹当零应变拉伸叠层坯料通过它们之间时,彼此至少有一定程度的啮合。
5、如权利要求4所述的方法,其特征在于其第二层的抑制是通过将吸力加到这第二层的相对周边部分来进行的,这第二层的相对周边部分至少直接相邻于其中一个啮合的波纹辊的波纹。
6、如权利要求4所述的方法,其特征在于其第二层的抑制是利用弹性压紧该层的相对周边部分来进行的,这层的相对周边部分至少直接相邻于其中一个啮合的波纹辊的波纹。
7、如权利要求6所述的方法,其特征在于其第二层的相对周边部分在整个增量坯料的拉伸过程中是压紧在至少一个啮合的波纹辊和一对位于另一波纹辊上的可弹性变形盘之间的。
8、如权利要求6所述的方法,其特征在于其第二层的相对周边部分在整个增量坯料的拉伸过程中,是被压紧在至少一个啮合的波纹辊和一对连续皮带之间的,其中皮带坏绕其波纹辊的一部分。
9、如权利要求1或2所述的方法,其特征在于其零应变拉伸叠层坯料的增量拉伸是在大致平行于坯料的运动方向的方向进行的。
10、如权利要求1或2所述的方法,其特征在于其零应变拉伸叠层坯料的增量拉伸是在大致垂直于坯料运动的方向的方向进行的。
11、如权利要求1或2所述的方法,其特征在于其零应变拉伸叠层坯料的增量拉伸是以非直线结构进行的。
12、如权利要求11所述的方法,其特征在于其零应变拉伸叠层坯料是以曲线结构进行的。
13、如权利要求1或2所述的方法,其特征在于其零应变拉伸叠层坯料还包括一第三基本未拉伸的层,这个第三基本未拉伸层是可拉伸的但比第一弹性层具有较小的弹性恢复并被固定到第一基本未拉伸的弹性层的表面,其中第一基本未拉伸弹性层与第二基本未拉伸层相对。
14、如权利要求13所述的方法,其特征在于其第二基本未拉伸层是不透水的。
15、如权利要求14所述的方法,其特征在于其第二基本未拉伸层是由聚合薄膜组成的。
16、如权利要求15所述的方法,其特征在于其第二基本未拉伸层包括一弹性的三维聚合薄膜。
17、如权利要求13所述的方法,其特征在于其第三基本未拉伸层是透水的。
18、如权利要求17所述的方法,其特征在于其第三基本未拉伸、透水层是由一无纺纤维材料组成的。
19、如权利要求17所述的方法,其特征在于第三基本未拉伸层包括一弹性多孔三维聚合薄膜。
20、一种增量拉伸一连续运动的零应变拉伸叠层坯料,使它在拉伸方向,至少在起始拉伸点的范围内获得弹性的改进方法,这方法特征在于包括如下步骤:
(a)将一零应变拉伸叠层坯料连续地送进到一对相对的施压器之间,这零应变拉伸叠层坯料包括一基本未拉伸的第一弹性层,而这第一弹性层是被间断地固定到一基本未拉伸的第二层,而这第二层包括一可拉伸的但比第一层具有较小的弹性恢复的连续坯料,施压器包括具有一垂直于坯料的运动方向的回转轴线的波纹辊,而这波纹辊具有包含有波纹的三维表面,它们的波纹彼此至少有一定程度的互补性;
(b)将相邻于要进行增量拉伸的连续运动的零应变拉伸叠层坯料部分的第一弹性层和第二可拉伸层的相对周边部分抑制住,以完全防止它在大体平行于拉伸方向的方向产生滑移或收缩;
(c)将位于相对抑制点之间的连续运动的零应变拉伸叠层坯料的部分进行增量拉伸,而第一弹性层和第二可拉伸层在连续运动的零应变拉伸叠层坯料通过波纹辊之间时,通过使包含有波纹辊波纹的相对三维表面彼此至少有一定程度的啮合使它们受到抑制,借此使第二可拉伸层被增量拉伸永久拉伸,使得该叠层坯料一旦将它的起始渐进拉伸力除去时,沿起始的拉伸方向,至少在起始拉伸点的范围内是弹性可拉伸的。
21、一种增量拉伸一连续运动的零应变拉伸叠层坯料,使它在拉伸方向,至少在起始拉伸点范围内获得弹性的改进方法,这方法特征在于包括如下步骤:
(a)将一零应变拉伸叠层坯料连续地送进到一对相对的施压器之间,这叠层坯料包括一基本未拉伸的第一弹性层,而这第一弹性层是被连续地固定到一基本未拉伸的第二层,而这第二层包括一可拉伸的但比第一层具有较小的弹性恢复的连续坯料,施压器包括具有一垂直于坯料运动方向的回转轴线的波纹辊,波纹辊具有包含有波纹的三维表面,它们的波纹彼此之间至少有一定程度的互补;
(b)将要进行增量拉伸的连续运动的零应变拉伸叠层坯料部分的第一弹性层和第二可拉伸层的相对周边部分抑制住,以完全防止它在大致平行于拉伸方向的方向产生滑移或收缩;
(c)将位于相对抑制点之间的连续运动的零应变拉伸叠层坯料的部分进行增量拉伸,而第一弹性层和第二可拉伸层在连续运动的零应变拉伸叠层坯料通过波纹辊之间时,通过使包含有波纹辊波纹的相对三维表面彼此至少有一定程度的啮合使它们受到抑制,借此使第二可拉伸层被增量拉伸永久拉伸,使得该叠层坯料一旦将它的起始增量拉伸力除去时,沿起始的拉伸方向,至少在起始拉伸点的范围内是可弹性拉伸的。
22、如权利要求20或21所述的方法,其特征在于其零应变拉伸叠层坯料有相对周边部分的抑制是至少直接在其中一个啮合的波纹辊的波纹附近施加吸力来实现的。
23、如权利要求20或21所述的方法,其特征在于其零应变拉伸叠层坯料相对周边部分的抑制是至少直接在其中一个啮合波纹辊的波纹附近将其边缘部分弹性压紧来实现的。
24、如权利要求23所述的方法,其特征在于其零应变拉伸叠层坯料的相对周边部分在整个增量坯料拉伸过程中是被压紧在至少其中一个啮合波纹辊和一对位于另一波纹辊上的一对弹性变形盘之间的。
25、如权利要求23所述的方法,其特征在于其零应变拉伸叠层坯料的相对周边部分,在整个增量坯料的拉伸过程中,是被压紧在至少一个啮合波纹辊和一对连续皮带之间的,连续皮带环绕波纹辊的一部分。
26、如权利要求20或21所述的方法,其特征在于其零应变拉伸叠层坯料的增量拉伸是在多个方向进行的。
27、一种增量拉伸一零应变拉伸叠层坯料,使它在拉伸方向,至少在起始拉伸点范围内获得弹性的改进装置,这种装置的特征在于包括:
(a)将一零应变拉伸叠层坯料送入一对具有三维表面的相对施压器之间的装置,施压器的三维表面有一定程度的互补性,零应变拉伸叠层坯料包括一基本未拉伸和第一弹性层,这第一弹性层被间断地固定到一基本未拉伸的第二层,这第二层是可拉伸的但比第一层具有较小的弹性恢复;
(b)将相邻于要进行增量拉伸的零应变拉伸叠层坯料部分的第二可拉伸层和第一层的周边部分抑制住以完全防止叠层坯料在大体平行于拉伸方向的方向产生滑移或收缩的装置;
(c)将位于相对抑制点之间的零应变拉伸叠层坯料进行增量拉伸的装置,在进行增量拉伸时第二可拉伸层和第一弹性层是受到抑制的,增量拉伸该零应变拉伸叠层坯料的该装置包括有使施压器的三维表面至少彼此啮合到一定程度的装置,因此使第二可拉伸层被增量拉伸永久地拉长,使得该叠层坯料一旦从它除去起始增量拉伸力便在起始拉伸方向,至少在起始拉伸点的范围内是可弹性拉伸的。
28、一种增量拉伸零应变拉伸叠层坯料,使它在拉伸方向,至少在起始拉伸点的范围内获得弹性的装置,该装置的特征在于:
(a)将一零应变拉伸叠层坯料送入一对具有三维表面的相对施压器之间的装置,施压器的三维表面有一定程度的互补性,零应变拉伸叠层坯料包括一基本未拉伸的第一弹性层,这第一弹性层是连续地固定到一基本未拉伸的第二层的,而这第二层是可拉伸的但比第一层具有较小的弹性恢复;
(b)将相邻于要进行增量拉伸的零应变拉伸叠层坯料部分的第二可拉伸层和第一层的周边部分抑制住,以完全防止叠层坯料在大致平行于拉伸方向的方向产生滑移或收缩的装置;
(c)将位于相对抑制点之间的零应变拉伸叠层坯料进行增量拉伸的装置,在进行增量拉伸时其第二可伸层和第一弹性层是受到固定的,增量拉伸该零应变拉伸叠层坯料的该装置包括有使施压器的三维表面彼此至少啮合到一定程度的装置,以此使第二可拉伸层被增量拉伸永久地拉长,使得该叠层坯料当一旦从它除去起始增量拉伸力时,便在起始拉伸方向,至少在起始拉伸点的范围内是可弹性拉长的。
29、如权利要求27或28所述的装置,其特征在于该相对的施压器包括有波纹辊,波纹辊具有大体上垂直于坯料运动方向的回转轴线,该施压器的三维表面包括有波纹,这些波纹,当该零应变拉伸叠层坯料通过波纹辊之间时,其彼此至少有一定程度的啮合。
30、如权利要求29所述的装置,其特征在于抑制该叠层坯料的装置包括有至少在其中一个啮合的波纹辊的波纹附近对该叠层坯料的相对周边部分施加力的装置。
31、如权利要求29所述的装置,其特征在于抑制该叠层坯料的装置包括有至少在其中一个啮合的波纹辊的波纹附近对叠层坯料的相对周边部分进行弹性压紧的装置。
32、如权利要求31所述的装置,其特征在于弹性压紧该叠层坯料的相对周边部分的装置包括至少一个啮合的波纹辊和一对直接位于另一波纹辊上的波纹附近的可弹性变形盘的装置。
33、如权利要求31所述的装置,其特征在于弹性压紧该叠层坯料的相对周边部分的该装置包括至少一个相啮合的波纹辊和一对连续皮带的装置,该连续皮带环绕该波纹辊的一部分并被直接定位在该波纹辊的波纹附近。
CN92101347A 1991-02-28 1992-02-28 增量拉伸零应变拉伸叠层坯料使其产生弹性的方法 Expired - Lifetime CN1038401C (zh)

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DE69219591D1 (de) 1997-06-12
PT100180B (pt) 1999-02-26
AU665753B2 (en) 1996-01-18
NZ241762A (en) 1995-04-27

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