CN109692078B - 制造透气网材的方法和设备以及相应的网材 - Google Patents

制造透气网材的方法和设备以及相应的网材 Download PDF

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CN109692078B
CN109692078B CN201811220350.3A CN201811220350A CN109692078B CN 109692078 B CN109692078 B CN 109692078B CN 201811220350 A CN201811220350 A CN 201811220350A CN 109692078 B CN109692078 B CN 109692078B
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welding
roll
web
anvil
welds
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CN109692078A (zh
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弗朗西斯科·达波恩特
塞拉菲诺·卢皮内蒂
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Fameccanica Data SpA
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Fameccanica Data SpA
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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
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/56—Supporting or fastening means
    • A61F13/64—Straps, belts, ties or endless bands
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及制造透气网材的方法和设备以及相应的网材。制造透气网材(W)的方法包括：将网材(W)供给到砧辊(16)的表面上，所述砧辊(16)能围绕其轴线(A)旋转，并具有与焊接元件(18)相配合的多个焊接凸起(20)；在所述焊接凸起(20)的顶面(22)上，于多个焊接点(44)处对所述网材(W)进行焊接，在所述焊接点(44)处形成围绕相应的焊接凸起(20)的相应的环形的焊缝(46)，并形成位于所述环形的焊缝(46)内侧且与所述焊接凸起(20)的顶面(22)相邻的相应的薄膜(48)；以及在进行所述焊接之后，通过剥离辊(36)来移除所述薄膜(48)，所述剥离辊(36)具有与所述焊接凸起(20)的所述顶面(22)相切的外表面。

Description

制造透气网材的方法和设备以及相应的网材
技术领域
本发明涉及制造透气网材的方法和设备。
本发明特别地提出了制造用于施加到一次性的吸收性卫生用品的腰部区域处的复合弹性网材。然而，本发明的范围不限于该可能的应用领域。例如，本发明也可用于制造单层的透气网材。
本发明还涉及特别地设计为用于制造一次性的吸收性卫生用品的透气网材。
背景技术
一次性的吸收性卫生用品的腰部区域通常设置有弹性网材，以便于使该吸收性用品能更好地贴合使用者的身体。例如，某些类型的一次性的吸收性卫生用品可由平行于彼此且在横向方向上彼此间隔开的两个连续的复合弹性网材形成，吸收芯在这两个复合弹性网材之间相对于网材的纵向方向而横向地延伸。
制造用于吸收性卫生用品的弹性网材的现有技术包括在两层无纺纤维之间设置处于张紧状态下的连续的弹性膜。这两层无纺纤维通常通过包括均匀地分布在复合网材的表面上的多个焊接点的焊接形式而焊接在一起。
为了提高吸收性卫生用品的舒适度，希望例如形成吸收性卫生用品的前腰带和后腰带的网材是透气的。
EP-A-1355604描述了一种设置有弹性侧板的吸收性卫生用品，该弹性侧板由两层无纺纤维形成，在这两层无纺纤维之间设置有弹性膜。无纺纤维层通过超声波焊接点而焊接在一起。超声波焊接将两个无纺层连接在一起，并形成通过弹性膜的通孔，给该弹性网材赋予透气特性。
发明内容
本发明的目的在于提出一种制造透气性较好的网材的方法和设备。
根据本发明，该目的可通过一种制造透气网材的方法来实现。该方法包括：将网材供给到砧辊的表面上，所述砧辊能围绕其轴线旋转，并具有与焊接元件相配合的多个焊接凸起；在所述焊接凸起的顶面上，于多个焊接点处对所述网材进行焊接，在所述焊接点处形成围绕相应的焊接凸起的相应的环形的焊缝，并形成位于所述环形的焊缝内侧且与所述焊接凸起的顶面相邻的相应的薄膜；以及在进行所述焊接之后，通过剥离辊来移除所述薄膜，所述剥离辊具有与所述焊接凸起的所述顶面相切的外表面。
优选地，所述剥离辊能围绕平行于所述砧辊的旋转轴线的轴线而旋转。
优选地，所述剥离辊能围绕其轴线沿着与所述砧辊的旋转方向相一致的方向旋转。
优选地，所述剥离辊的圆周速度大于所述砧辊的圆周速度。
优选地，所述剥离辊的圆周速度比所述砧辊的圆周速度要大至少10％。
优选地，所述剥离辊在其外表面上具有多个人字形的肋，所述肋具有相对于所述砧辊的所述焊接凸起的顶面而言的从内到外的相对运动。
根据本发明，该目的也可通过一种制造透气网材的设备来实现。该设备包括：焊接单元，所述焊接单元包括砧辊，所述砧辊具有多个带有相应的顶面的焊接凸起，所述焊接单元还包括焊接元件，所述焊接元件与所述焊接凸起的顶面相配合；以及剥离辊，所述剥离辊位于所述焊接元件的下游处，并具有与所述焊接凸起的所述顶面相切的外表面。
优选地，所述剥离辊被驱动为以比所述砧辊的圆周速度要大至少10％的圆周速度来旋转。
优选地，所述剥离辊具有位于其外表面上的多个人字形的肋，所述肋从所述剥离辊的外表面的中心处向外边缘处延伸。
根据另一方面，本发明的目的在于提出一种具有较好的透气性的透气弹性复合网材。
根据本发明，该目的可通过一种透气网材来实现。该透气网材包括至少一个层和根据焊接形式而分布在所述网材上的多个焊接点，其中，所述焊接点具有相应的环形的焊缝，并且所述焊接点具有位于所述环形的焊缝内侧的相应的通孔。
优选地，透气网材包括第一无纺层和第二无纺层，以及位于所述无纺层之间的弹性膜，其中，所述环形的焊缝将所述第一无纺层和所述第二无纺层连接在一起，并穿过所述弹性膜。
优选地，所述弹性膜具有多个围绕相应的焊缝的通孔。
优选地，所述弹性膜在所述环形的焊缝处焊接在所述第一无纺层和所述第二无纺层上。
权利要求书形成了相对于本发明而在这里所提出的公开内容的一部分。
附图说明
下面将参照附图来对本发明进行详细的描述，这些附图仅作为非限制性实施例而给出，其中：
图1显示了用于制造透气复合弹性网材的设备的示意性侧视图；
图2显示了根据图1中的箭头II所示的俯视图；
图3显示了由图2中的箭头III所指出的部分的部分放大图；
图4显示了沿着图3中的线IV-IV的部分截面图；
图5显示了由图2中的箭头V所指出的剥离辊的立体图；
图6、图7和图8显示了由图1中的箭头VI、VII和VIII所指出的细节处的大幅放大截面图；且
图9显示了图8中的变体的截面图。
具体实施方式
参照图1，附图标记10为制造透气网材的设备的示意性标识。附图显示了该设备用于制造多层的复合网材的情况。然而，根据本发明的设备和方法也可用于制造单层的弹性或非弹性的透气网材。
设备10包括焊接单元12，该焊接单元12包括能围绕着纵向轴线A旋转的砧辊16，以及与该砧辊16相配合的焊接元件18。在图1所示的实施例中，焊接元件18为超声波焊接装置的超声波发生器。
参照图1-4，砧辊16的外表面包括由小的销钉形成的具有顶面22(参见图4)的多个凸起20，该凸起与作为焊接元件18的超声波发生器相配合，以在移动的网材上形成超声波焊接点。凸起20可具有如图4所示的截头锥轮廓。凸起20的顶面22可具有任意的形状，例如圆形或多边形(例如，长斜方形)。凸起20设置在砧辊16的外表面上，从而限定了与移动的网材上的焊接点的分布相对应的焊接形式。例如，如图2和图3所示，凸起20可沿着一系列的正弦线而设置。焊接形式的形状可根据网材的表面上所需的美学效果而改变。
在一个作为替代的实施方案中，焊接单元12可以是热力焊接单元。在这种情况下，作为焊接元件18的超声波发生器可替换为按压在砧辊16的外表面上的加热焊接辊。
设备10包括引入辊24，该引入辊将复合弹性网材W引导至砧辊16的外表面上。网材W保持在砧辊16的外表面上，并由于砧辊16的旋转而穿过由砧辊16的外表面和作为焊接元件18的超声波发生器形成(或者作为替代，在热力焊接的情况下，位于砧辊16与焊接辊之间的接触表面之间的)的焊接区域34。
复合网材W由多个层接合在一起形成。在附图所示的实施方案中，网材W为弹性复合网材，包括两个无纺纤维层NW1、NW2，以及包围在两个无纺纤维层NW1、NW2之间的弹性膜EF。如上文所述，网材W可以是单层的弹性或非弹性的网材。
设备10可包括供给组件26，该供给组件设置为能将包括网材W的层供给到引入辊24上。在图1所示的实施例中，供给组件26可包括多对辊子28、30、32，它们分别用于两个无纺纤维层NW1、NW2和弹性膜EF。供给弹性膜EF的辊子32可被控制为能相对于弹性膜的非变形状态来拉伸弹性膜EF。弹性膜EF可被拉伸为具有大约10-600％，优选地50-200％的延伸量。
网材W保持在砧辊16的外表面上，并沿着由图1中的箭头B所示的方向、以与砧辊16的圆周速度相等的速度V前进。网材W穿过焊接区域34，在那里，网材W受到能对网材W进行点焊的焊接操作，该焊接操作具有与凸起20的形式相对应的焊接形式。
设备10包括剥离辊36，该剥离辊在焊接区域34的下游处与砧辊16的外表面相配合。剥离辊36能围绕平行于砧辊16的旋转轴线A的轴线C旋转。剥离辊36具有与砧辊16的外表面相切的外表面。特别地，剥离辊36的外表面与砧辊16的凸起20的顶面22相切。
如图2和图5所示，剥离辊36具有圆柱形表面，在该圆柱形表面上形成有多个人字形肋38。剥离辊36定位成使得人字形肋38的外表面基本上与砧辊16的凸起20的顶面22相切，优选地在它们之间具有基本上为零的间隙。可设置有调节系统，该调节系统可确保剥离辊36相对于砧辊16的正确定位。剥离辊36可保持以较轻的接触压力来与砧辊16的外表面相接触，其一个目的在于确保剥离辊36与砧辊16之间的接触。剥离辊36与砧辊16之间的较高的接触力不会影响设备10的运行，但是会导致剥离辊36和/或砧辊16的过早磨损。
在运行过程中，剥离辊36被驱动为沿着与砧辊16的旋转方向相一致的方向围绕其轴线C旋转。剥离辊36的圆周速度V1大于砧辊16的圆周速度V。在一个或多个实施方案中，剥离辊36的圆周速度比砧辊16的圆周速度V大至少10％。
参照图2和图5，剥离辊36的人字形肋38具有位于剥离辊36的外表面的中心位置处的顶部。肋38朝向辊36的外侧分开。如图2中的箭头D所示意性显示的那样，相对于砧辊16的接触区域，肋38从砧辊16的中心朝侧边移动。
位于砧辊16的外表面上的网材W穿过剥离辊36与砧辊16之间的接触区域。在焊接元件18已经在网材W上进行点焊之后，剥离辊36作用在网材W上。
释放辊40设置在剥离辊36的下游处，该释放辊使网材W与砧辊16的外表面分离。
设备10可包括位于剥离辊36与砧辊16之间的接触区域之下的废料收集元件42。废料收集元件42可与抽吸源相连。
网材W至少部分地由能通过超声波焊接或热压焊接而焊接的热塑材料形成。在所显示的网材W包括包围在两个无纺纤维层NW1、NW2之间的弹性膜EF的实施例中，无纺纤维层包括热塑性纤维(例如，聚酯，聚丙烯等)。弹性膜可由相对于无纺纤维层NW1、NW2的热塑性纤维相容或不相容的材料形成。为了本文中的目的，可焊接在一起的两种材料被认为是可相容的，而不可相容的材料不能彼此焊接在一起。在所示的实施例中，两个无纺纤维层NW1、NW2是彼此相容的。弹性膜EF可与形成无纺纤维层NW1、NW2的材料相容或不相容。
图6显示了网材W在焊接区域34下游且在剥离辊36的上游的部分上的焊接点的大幅度放大的横截面。网材W在焊接元件18与砧辊16的凸起20的顶面22之间被压缩。在该压缩之后，能在凸起20的周围实现热塑性材料的局部熔化。在焊接区域34的下游处，在相应的凸起20处的网材W上形成多个焊接点44。各个焊接点44均包括在相应的凸起20周围延伸的环形的焊缝46，以及在相应的凸起20的顶面22处的环形的焊缝46内延伸的薄膜48。环形的焊缝46和薄膜48由熔化的热塑性材料形成。薄膜48可具有大约0.01mm的厚度。在图6所示的实施例中，两个无纺纤维层NW1、NW2在各个焊接点44处通过环形的焊缝46而焊接在一起。在图6所示的实施例中，弹性膜EF由不能与形成无纺纤维层NW1、NW2的材料相容的材料制成。因此，在这种情况下，焊接形成了穿过弹性膜EF的通孔50。在这种情况下，弹性膜EF不与无纺纤维层NW1、NW2焊接在一起。在弹性膜EF由能与形成无纺纤维层NW1、NW2的材料相容的材料制成的情况下，弹性膜EF与环形的焊缝46焊接在一起(图9)。
在焊接步骤的下游处，网材W受到用于将形成在焊接点44处的薄膜48移除的操作。薄膜48的移除所进行的同时，焊接点44接合在砧辊16的相应的凸起20上。
薄膜48的移除操作可通过使网材W穿过剥离辊36与砧辊16之间的接触区域来进行。
如图7所示，剥离辊36的肋38相对于凸起20的顶面22以速度ΔV＝V1-V来移动，其中，V1和V分别为剥离辊36的圆周速度和砧辊16的圆周速度。如图7所示，剥离辊36的肋38可移除薄膜48。由于凸起20和肋38的相向表面以小于膜48的厚度的距离彼此间隔开，并存在相对运动，所以能通过切削或磨蚀作用来移除薄膜48。剥离辊36的肋38的人字形构造能确保在凸起20处肋38具有朝向网材W的边缘处的相对移动。这能确保网材固定地保持在砧辊16的表面上，并能避免网材W的起皱或放松。通过剥离辊36而移除的薄膜48可由位于剥离辊36和砧辊16之间的接触区域之下的废料收集元件42收集在一起，并被吸入到废料收集容器中。
在剥离辊36的下游处，网材W通过释放辊40而与砧辊16的表面分离开。
在释放辊40的下游处，网材W(在焊接点44处)具有如图8所示意性显示的结构。网材W具有多个焊接点44，各个焊接点均通过由无纺纤维层NW1、NW2的纤维的局部熔化而得到的热塑性材料的焊缝46而形成。网材W具有多个位于相应的环形的焊缝46内侧的通孔52。弹性膜EF具有围绕该环形的冠状物46的通孔50。通孔52允许空气通过网材W，并能为网材W赋予较高的透气性。网材W也可具有位于弹性膜EF的孔50与各个焊接点44的环形的焊缝46之间的环形空间中的透气区域。在这些区域中，网材W的透气性由无纺纤维层NW1、NW2的孔隙率所提供。
图9显示了弹性材料膜EF由与形成无纺纤维层NW1、NW2的材料相容(因此而能焊接)的材料制成。在这种情况下，在焊接点44处，弹性膜EF焊接到环形的焊缝46上。在这种情况下，网材W的透气性仅由相应的环形的焊缝46内侧的通孔52所提供。
根据本发明的设备和方法可使用超声波焊接单元或热力焊接单元，并可具有任意形状或结构的焊接形式。根据本发明的设备和方法允许在三层式弹性网材(其中弹性膜可能会使得网材不透气)的情况下得到透气复合弹性网材。
当然，在不损害本发明的原则的情况下，结构和实施方案的细节可相对于所描述和显示的内容广泛地变化，而不会因此而背离由随附的权利要求书所限定的本发明的范围。

Claims (10)

1.一种制造透气网材(W)的方法，包括：
将网材(W)供给到砧辊(16)的表面上，所述砧辊(16)能围绕其轴线(A)旋转，并具有与焊接元件(18)相配合的多个焊接凸起(20)，
在所述焊接凸起(20)的顶面(22)上，于多个焊接点(44)处对所述网材(W)进行焊接，在所述焊接点(44)处形成围绕相应的焊接凸起(20)的相应的环形的焊缝(46)，并形成位于所述环形的焊缝(46)内侧且与所述焊接凸起(20)的顶面(22)相邻的相应的薄膜(48)，以及
在进行所述焊接之后，通过剥离辊(36)来移除所述薄膜(48)，所述剥离辊(36)具有与所述焊接凸起(20)的所述顶面(22)相切的外表面。
2.根据权利要求1所述的方法，其特征在于，所述剥离辊(36)能围绕平行于所述砧辊(16)的旋转轴线(A)的轴线(C)而旋转。
3.根据权利要求1或2所述的方法，其特征在于，所述剥离辊(36)能围绕其轴线(C)沿着与所述砧辊(16)的旋转方向相一致的方向旋转。
4.根据权利要求1所述的方法，其特征在于，所述剥离辊(36)的圆周速度(V1)大于所述砧辊(16)的圆周速度(V)。
5.根据权利要求4所述的方法，其特征在于，所述剥离辊(36)的圆周速度(V1)比所述砧辊(16)的圆周速度(V)要大至少10％。
6.根据权利要求1所述的方法，其特征在于，所述剥离辊(36)在其外表面上具有多个人字形的肋(38)，所述肋具有相对于所述砧辊(16)的所述焊接凸起(20)的顶面(22)而言的从内到外的相对运动。
7.一种制造透气网材(W)的设备，包括：
焊接单元(12)，所述焊接单元包括砧辊(16)，所述砧辊具有多个带有相应的顶面(22)的焊接凸起(20)，所述焊接单元还包括焊接元件(18)，所述焊接元件与所述焊接凸起(20)的顶面(22)相配合，以及
剥离辊(36)，所述剥离辊位于所述焊接元件(18)的下游处，并具有与所述焊接凸起(20)的所述顶面(22)相切的外表面。
8.根据权利要求7所述的设备，其特征在于，所述剥离辊(36)被驱动为以比所述砧辊(16)的圆周速度(V)要大至少10％的圆周速度(V1)来旋转。
9.根据权利要求7或8所述的设备，其特征在于，所述剥离辊(36)具有位于其外表面上的多个人字形的肋(38)，所述肋从所述剥离辊(36)的外表面的中心处向外边缘处延伸。
10.一种透气网材(W)，包括至少一个层和根据焊接形式而分布在所述网材(W)上的多个焊接点(44)，其中，所述焊接点(44)具有相应的环形的焊缝(46)，并且所述焊接点(44)具有位于所述环形的焊缝(46)内侧的相应的通孔(52)，所述透气网材包括第一无纺层和第二无纺层，以及位于所述无纺层之间的弹性膜(EF)，其中，所述环形的焊缝(46)将所述第一无纺层和所述第二无纺层连接在一起，并穿过所述弹性膜(EF)，所述弹性膜(EF)具有多个围绕相应的焊缝(46)的通孔(50)。
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