CN1087302A - 制造一种薄膜或膜片形产品的方法和装置 - Google Patents

制造一种薄膜或膜片形产品的方法和装置 Download PDF

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CN1087302A
CN1087302A CN93108905A CN93108905A CN1087302A CN 1087302 A CN1087302 A CN 1087302A CN 93108905 A CN93108905 A CN 93108905A CN 93108905 A CN93108905 A CN 93108905A CN 1087302 A CN1087302 A CN 1087302A
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吉亚科迈提·克劳狄欧
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Abstract

一种形成卷材(N)的方法，该卷材可渗液体并用 来隔开两围绕物以允许液体在一个方向上从围绕物 之一上流向另一围绕物，该方法包括使卷材在两个相 互压靠的两旋转圆柱体(5，7)之间通过，圆柱体之一 (7)具有带突块的表面用来在卷材(N)上穿孔。带突 块圆柱体(7)的圆周速度大于另一圆柱体(5)的圆周 速度，结果是在两圆柱体(5，7)的表面之间有相应的 滑动作用。

Description

本发明涉及一种形成合成薄膜、膜片或卷材的方法，这些材料用来形成如卫生巾、尿布的外层或其它产品如过滤件。特别是，本发明涉及的方法包括在合成薄膜或膜片或卷材上穿孔以产生多个孔眼，从而使得液体能从吸收体的外部渗入到该吸收体内的材料件上。
更特别地是，本发明涉及到一种穿孔的薄膜或膜片材料的制造方法，这种材料被用来隔开两个围绕物，在两个围绕物之间的液体只能在一个方向上流动，而不能在相反方向上流动。在下面的描述中，将主要涉及到尿布或卫生巾。然而，应当强调用本发明方法生成的产品可用在任何需要能渗透液体的薄膜的场合，并且该液体必须仅仅在一个方向流过薄膜或膜片，正如在一个过滤件中的那样。
美国专利4，780，352公开了一种由无纺薄膜构成的产品，在整个薄膜上分布有许多孔眼以便使液体流过。按照这项专利，将材料在两个反转辊之间通过以使材料穿孔，反转辊相互的圆周速度是相同的，并且该圆周速度与材料的前进速度也是相同的。两辊中的一个有突块，当这根辊与另一辊配合时就在材料上穿孔。
本发明的目的是提供一种形成薄膜和/或膜片和/或卷材的方法和装置，在薄膜（膜片，卷材）上能得到一特殊构造的以这样的方式即直接使液体流动的孔眼，从而薄膜能够从吸收体的外面渗透到里面，然而不会从里面漏出。
本发明的进一步目的是提供一种制造薄膜和/或膜片的方法，该薄膜和/或膜片能有效地将吸收体内的材料与使用者的皮肤隔离。
本发明的进一步目的是提供一种制造薄膜或膜片或组合形式的产品的方法和装置，这种产品能够形成一障碍物以限定和隔开两围绕物，在两围绕物之间的液体必须在一个方向流动，而不能在相反方向流动。
实质上，按照本发明的方法，薄膜和/或膜片在第一旋转圆柱体和第二旋转圆柱体之间通过，第一圆柱体的表面基本上是光滑的，而第二圆柱体的表面如此分布，即具有一系列突件，并压住第一圆柱体，光滑圆柱体的圆周速度以及薄膜和/或膜片材料的前进速度小于带突件的圆柱体的圆周速度。
这样产生了滑动作用，这一作用作用于材料上靠薄膜材料的塑性变形将形成多个孔眼，结果是，除了在孔眼中有部分分离的材料，还生成部分分离的材料条带，它位于在两圆柱体之间通过的薄膜材料的输送方向上。这些条带的作用是允许液体从薄膜和/或膜片材料的一侧流到另外的防止液体在相反方向流回的一侧（更特别地是，从带突件的圆柱体作用其上的侧部流向与光滑圆柱体相接触的侧部）。
按照本发明的方法可有益地用于低基础重量如8-80gsm的卷材。按照本发明方法加工出的薄膜或膜片可以由无纺的如梳刷纤维构成的单层薄膜或是由纺织纤维（具有适当的疏水性）构成的单层薄膜或是塑料薄膜形成的。本方法也可以用于如由两层或多层梳刷纤维薄膜构成的合成材料或是由粘到塑料薄膜上的纤维薄膜构成的合成物。典型地，也可以在使用梳刷纤维薄膜的每一侧使用塑料薄膜。利用上述用来产生专门孔眼的同样的滚压和滑动作用也可以得到几层牢固地夹在一起的材料。
由于孔眼（此后用条带）靠的非常近，因此用本发明方法产生的薄膜的总厚度远远地大于其初始材料厚度。例如，开始时薄膜或膜片的厚度为30微米，而总厚度能达到300微米。这样就可以用非常少的材料产生非常厚的以及具有非常好的隔离特性的薄膜。如果采用单一的，即非合成的薄膜或膜片的话，这一优点特别明显。
在一特定的较佳实施例中，特别是有效地加工塑料薄膜材料，比如聚乙烯和它的派生物或其它合适的塑料材料时，圆柱体之一或是两者可加热到一个适宜的温度。热量增加了塑料材料的粘度，从而促使它的穿孔以及与基材部分分离的材料条带的变形。有利地是，两圆柱体的温度可以相互独立地调节。支承着突块的圆柱体的表面温度最好是高于另一圆柱体的温度。
两圆柱体之间的压力，以及滚压膜片或薄膜材料的压力可方便地加以改变以适合于所用的基材。而且速度差以及旋转圆柱体表面之间的滑动均可在预设的极限内变化以适应于所用的材料。特别是，滑动可在10-50%之间变化，最好是在15-25%之间。圆柱体的表面温度可设定在70-240℃之间，特别是在100-180℃之间。两滚筒之间的线压可在如120-200kg/cm范围内变化，最好是在130-150kg/cm范围内变化。
为了生产用于特殊产品的半成品，例如婴儿或不能自制病人用的尿布，妇女卫生巾等上用的半成品，按照本发明的方法，可以沿着连续的长条带上或者沿着未在卷材的全部长度上伸展的区域对薄膜或膜片形的材料进行穿孔。结果是，在将这种薄膜用到成品上时，可以得到这样一个区域，即在该区域上液体能（通过孔眼）从一侧流向另一侧，如流向吸收体内部，并且还能得到一个完全抗渗区，在该区域液体不能流回。当然，穿孔区要在被吸收液体流至区域上方的吸收体上。
按照本发明的装置包括一对相互紧压的旋转圆柱体，在两圆柱体之间通过欲加工的薄膜或卷材;第一圆柱体是光滑的，而第二圆柱体具有突块以产生孔眼。有突块的圆柱体的圆周速度高于光滑圆柱体的圆周速度，从而在两圆柱体之间被滚压的薄膜或膜片材料承受滑动作用以及随后的塑性变形。
有利地是，圆柱体之一或两者均可有加热装置以使其外表面保持适当温度，从而促使卷材的塑性变形，两圆柱体的加热装置优点在于可独立调节。
带突块的圆柱体包括一系列位于整个圆柱体表面上或是在局部区域例如在特定的环形区域上方的相同突块，从而使生成的材料在沿所限定的长条带上带孔眼，而在一条带和相邻条带之间为非孔眼区。也能在由非穿孔区域所限定的区域上方产生带孔的卷材，最好是，采用的圆柱体的突块具有不同的高度和任选的不同形状，特别是如在要穿孔区域的突块较高，而在非穿孔区域较低。卷材的具有较少突块的区域被充分地进行滚压以确保形成薄膜的各种任选层之间的粘结，但在此处并不穿孔。
本发明方法和装置的进一步特点在附加的权利要求中。
在下面的说明和附图中将更加明确地理解本发明，附图示出了本发明的一实用的，非限定的实施例。在附图中：
图1示出了按照本发明装置的一可行实施例的示意图，
图2示出了一可行实施例中带柱栓圆柱体部分的前视图，
图3示出了沿图2中Ⅲ-Ⅲ线的剖视图，
图4和图5类似于图2和图3，示出了带柱栓圆柱体表面不同的构造，
图6示出了部分产品的平面视图，图6A示出了沿材料通过装置的送进方向即沿图6中VIA-VIA线剖去的剖视图，而图7是沿着垂直于材料送进方向即沿图6Ⅶ-Ⅶ线剖的剖视图，
图8示出了吸收体的示意剖视图，
图9示出了在条带上穿孔的部分薄膜或膜片，
图10示出了部分带有突块的圆柱体的示意剖视图，它适用于产生具有非穿孔区与穿孔区联接的薄膜或膜片。
首先参见图1，装置（在这个实施例中）具有支承第一卷材辊R的机构Ⅰ，卷材可以是塑料薄膜。卷材N从辊R1上退绕并重新卷绕到由支承机构3所支承的辊R2上。支承机构3具有电机（未示出），它使辊R2旋转以拉住卷材N并将其卷起。在两个支承机构1和3之间有一对分别用5和7表示的圆柱体。在图示实施例中，圆柱体5位于卷材N之下并顺时针方向旋转。圆柱体5具有由弹性变形材料如橡胶层5A所限定的外表面。这种材料可以与典型地用在卫生纸的纸材压纹生产中以及类似产品生产中设备上所用材料相同。并不排除使用一种具有钢外表面的圆柱体5。
与圆柱体5相配合的是以逆时针方向旋转的圆柱体7。两个圆柱体5和7以一种最好是可调节的压力相互压靠。将圆柱体7分布成使其工作表面具有几何分布的突块，圆柱体7突块的可能形状将参照相应的图2-5和图9加以详细地说明。
圆柱体7以一个比下面的圆柱体5的圆周速度要高的圆周速度旋转，其高出值可按百分率予以调整。这样在两个圆柱体的表面之间产生相对的滑动作用，从而使在两圆柱体5和7之间通过的卷材N内的滚压和滑动作用对材料产生影响，这种材料将在下面参考图6和7加以说明。
最好使圆柱体7保持在一高温下，例如，靠由管9引入的高温下的蒸汽或导热油，而管9经一适当的旋转接头与圆柱体7的内部相连。相类似地，最好由类似系统加热圆柱体5。带热流体的加热方式可以被电阻加热方式或其它任何加热方式所替代。
图2和3示出了圆柱体7突块的一种可能的形式。在这个实施例中，圆柱体7的方形基面上具有一个截头棱锥突块的格，在图3中用P1加以表示。图4和5示出了圆柱体7突块的另一种可能的形式，该形式的特点是突块P2一般具有截头圆锥形，它的端部13基本为圆柱形而它的前表面15与圆柱体5的光滑表面相配合。
也可以采用其它形式来分布圆柱体7。这些形式的选择应考虑成品的美学上和技术上的要求以及圆柱体7的制造成本。
在卷材N从圆柱体5和7之间通过时，卷材产生塑料变形，这种变形在圆柱体7的突块P1或P2穿透卷材时在材料上形成穿孔。与形成卷材N的基材相分离的材料并没有完全除去，至少孔圆周部分仍与基材相连并处于卷材N的前进方向，即位于图1示出的箭头f方向。在每个孔中部分分离材料所处的方向是由圆柱体5和7的两个旋转表面间的相对的滑动作用所决定的，图6，6A和7分别示出了一对圆柱体5和7下游的卷材N的平面视图和沿VIA-VIA和Ⅶ-Ⅶ的剖视图。图6A和7清楚地示出了孔F和位于材料前进方向上用A表示的部分分离的材料条带。
与卷材N的每个孔相连的条带A的作用如一种单向阀，即允许液体容易地从上表面流到卷材的下表面（相对于图6和7示出的方向），而在相反方向阻止其回流。当卷材被用来形成如卫生巾的最外层时，如图8所示的那样，将条带这样放置即使其着卫生巾的内部，也就是朝向吸收材料MA的主体。这样，要吸收的液体可容易地从卫生巾的外侧流到内部，而在相反方向上的回流实际上由于条带A的存在被阻止了。
采用塑料薄膜的卷材N的主要优点在于基材的无孔区域实际上是不透水的。与由梳刷纤维薄膜和/或任何纺织纤维所生成的卷材相比较，这种结构减少了液体经材料N的未破损区即无孔区从吸收体的内部流到外部的回流现象。
使用塑料薄膜的进一步优点在于，在薄膜制造生产线上除去了梳理机和/或其它纺织设备。
所述的方法也可以使用如前所述的合成卷材。
在某种特定的应用中，如用于婴儿尿布的制造中，有利的是仅仅外层的中心区是可渗透的，即尿仅仅流向此处，然而有利的是在围绕区防止液体的流通，从而将尿布的内部与外部相隔离，这样避免了与被吸收液的任何接触。为此，在本发明的改进实施例中，圆柱体7可具有主要为完整的或局部环形的分布区域，且环形区域是不滑的。在这种情况下，从成对圆柱体中露出的卷材N具有如图9所示的穿孔区和非穿孔区。在该图中N表示一片卷材，它具有穿孔区A1和未破损区A2。在尿布的制造中，切下卷材N并以这样的方式围绕着内吸收材料，卷绕，即穿孔条带或区域A1基本沿着尿布的贴着使用者放置的表面中心线放置。
代替具有平滑区和带突块区的圆柱体，是采用图10所示的有不同高度突块的圆柱体，该图示出的圆柱体的表面部分是沿轴平面的剖视图。图10示出了突块23高度为H的区域21，以及突块27高度h小于H的区域25，高度H和h是这样决定的，即在将卷材N于光滑圆柱体5和圆柱体7之间滚压时，在相应于突块23突出的位置处产生穿孔卷材，而在区域25中仅仅滚压，结果是形成包括相互重叠而未穿孔的薄膜。圆柱体5表面和突块27之间的滚压并没有越过变硬的材料。图10的形式可做出如圆柱体7的均匀加工表面，然后将一些区域如23区域喷砂处理，这样此处突块27的高度减小。喷砂结果是突块27具有略微倒圆的前表面，它在使用中有非常好的作用。
在一较佳实施例中，用聚丙烯薄膜作卷材。圆柱体5和7之间的线压设定为140kg/cm，滑动百分为数为18%。换言之，前进速度为40m/min，下部圆柱体5的圆周速度相等于卷材N和前进速度，而上部圆柱体7的速度为48m/min。这样获得最好结果时圆柱体7的表面温度大约维持在120℃，而圆柱体5的温度大约为110℃。

Claims (24)

1、一种形成卷材的方法，该卷材能渗透液体并用来隔开两围绕物以允许液体在一个方向上从围绕物之一流向另一围绕物，在该方法中，卷材在相互压靠在一起的两反转圆柱体之间通过，圆柱体之一的表面上具有将卷材穿孔的突块，该方法的特征在于带突块圆柱体的圆周速度高于另一圆柱体的圆周速度，在两圆柱体的表面间具有相对的滑动作用。
2、按照权利要求1的方法，其特征在于，至少两圆柱体之一被加热。
3、按照权利要求1的方法，其特征在于，两圆柱体均被加热，两圆柱体的表面温度可相互分开调节。
4、按照权利要求之一或多个的方法，其特征在于，两圆柱体之间的滑动是由于圆周速度不同所引起的，是在较低速圆柱体圆周速度的10-50%之间进行滑动。
5、按照权利要求4的方法，其特征在于，滑动在15-25%之间。
6、按照权利要求2，3，4或5的方法，其特征在于，带突块的圆柱体表面温度在70-240℃之间。
7、按照权利要求2，3，4，5或6的方法，其特征在于，光滑圆柱体的表面温度在70-240℃之间。
8、按照上述权利要求之一或多个的方法，其特征在于，两圆柱体相互压靠在一起的压力在120-220kg/cm2之间。
9、按照上述权利要求之一或多个的方法，其特征在于，卷材是织成的纺织材料薄膜或无纺薄膜或梳刷纤维薄膜。
10、按照权利要求1-8之一或多个的方法，其特征在于卷材是塑料薄膜。
11、按照权利要求1-8之一或多个的方法，其特征在于，卷材是由多层薄膜构成，每层包括纺织纤维或塑料薄膜。
12、按照上述权利要求之一或多个的方法，其特征在于，卷材在限定区域被穿孔。
13、用于制造穿孔卷材的装置，该卷材用来隔开两围绕物并允许液体在一个方向上从第一围绕物流向另一围绕物，该装置包括输送卷材的机构，以及一对相互压靠的反转圆柱体，卷材在两圆柱体之间通过，第一圆柱体是光滑的，而第二圆柱体具有突块，该装置的特征在于，带突块的圆柱体圆周速度大于光滑圆柱体的圆周速度。
14、按照权利要求13的装置，其特征在于，至少两圆柱体之一具有加热其表面的加热机构。
15、按照权利要求14的装置，其特征在于，两圆柱体均装有加热机构，加热机构允许分开调节两圆柱体的表面温度。
16、按照权利要求13-15之一或多个的装置，其特征在于，可调节带突块圆柱体与光滑圆柱体之间的圆周速度差。
17、按照权利要求13-16之一或多个的装置，其特征在于，可调节两圆柱体之间的压力。
18、按照权利要求13-17之一或多个的装置，其特征在于，带突块的圆柱体的外表面具有带突块的区域和光滑的区域。
19、按照权利要求13-17之一或多个的装置，其特征在于，带突块的圆柱体具有较高突块区域和较低突块区域。
20、按照权利要求13-19之一或多个的装置，其特征在于，光滑圆柱体具有一弹性变形的圆柱形表面，该表面包括一层由橡胶材料或纺织纤维制成的覆盖层。
21、按照权利要求13-19之一或多个的装置，其特征在于，光滑圆柱体的外表面由金属制成。
22、一种其表面上具有多个孔眼的卷材或薄膜产品，其特征在于，卷材或薄膜的已从相应孔中除去的基材与基材不完全分离而形成一在卷材或薄膜表面上延伸的条带（A）。
23、按照权利要求22的卷材或薄膜产品，其特征在于，它是由单层塑料薄膜形成。
24、按照权利要求22的卷材或薄膜产品，其特征在于，它是多层结构产品，包括中间塑料薄膜层和由纤维制成的外层。
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JPH06198780A (ja) 1994-07-19
DE69210403T2 (de) 1996-09-05
CZ244393A3 (en) 1994-05-18
ES2086111T3 (es) 1996-06-16
DE69210403T3 (de) 2000-08-03
EP0598970A1 (en) 1994-06-01
KR0134079B1 (en) 1998-04-21
GR3033426T3 (en) 2000-09-29
US5709829A (en) 1998-01-20
CN1040958C (zh) 1998-12-02
KR940011051A (ko) 1994-06-20
GR3019813T3 (en) 1996-08-31
JP3150010B2 (ja) 2001-03-26
DE69210403D1 (de) 1996-06-05
CZ287887B6 (cs) 2001-03-14
HU9303253D0 (en) 1994-03-28
BR9304738A (pt) 1994-05-24
EP0598970B2 (en) 2000-04-05
US5814389A (en) 1998-09-29
ATE137433T1 (de) 1996-05-15
DK0598970T4 (da) 2000-07-17
EP0598970B1 (en) 1996-05-01
ES2086111T5 (es) 2000-06-01
HUT67098A (en) 1995-02-28
TW257730B (zh) 1995-09-21
CA2103196A1 (en) 1994-05-18
CA2103196C (en) 1997-04-15
DK0598970T3 (da) 1996-06-03
HU213659B (en) 1997-09-29

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