CN109843589A - 利用具有砧图案的旋转粘合系统形成复合纤网的方法 - Google Patents

利用具有砧图案的旋转粘合系统形成复合纤网的方法 Download PDF

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CN109843589A
CN109843589A CN201680090135.9A CN201680090135A CN109843589A CN 109843589 A CN109843589 A CN 109843589A CN 201680090135 A CN201680090135 A CN 201680090135A CN 109843589 A CN109843589 A CN 109843589A
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energy
bonding patterns
machine direction
material web
auxiliary
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CN109843589B (zh
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G·J·拉亚勒
J·K·西克
K·J·沃纳
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Kimberly Clark Worldwide Inc
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Kimberly Clark Worldwide Inc
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    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B29C66/8362—Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • 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
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • 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
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15699—Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
    • 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
    • A61F13/15577—Apparatus or processes for manufacturing
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    • A61F13/15739—Sealing, e.g. involving cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary sonotrode
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    • B29C66/223—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns being in the form of a triangle wave or of a sawtooth wave, e.g. zigzagged
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/23—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
    • 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
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Textile Engineering (AREA)
  • General Health & Medical Sciences (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Vascular Medicine (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Epidemiology (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Manufacturing & Machinery (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Laminated Bodies (AREA)
  • Folding Of Thin Sheet-Like Materials, Special Discharging Devices, And Others (AREA)
  • Replacement Of Web Rolls (AREA)

Abstract

本文公开了一种将第一材料纤网粘合到第二材料纤网以形成复合材料的方法。首先，提供在机器方向上移动的第一材料纤网和第二材料纤网。所述材料纤网通过在横跨机器方向上横向延伸的第一能量施加装置。所述第一能量施加装置包括主粘合图案和辅粘合图案。所述主粘合图案结合所述辅粘合图案在所述横跨机器方向上连续延伸横跨所述第一能量施加装置。另外，提供了第二能量施加装置。所述第二能量施加装置在所述横跨机器方向上移动，且由此在所述第一能量施加装置上方延伸所述第二能量施加装置，并且组合操作所述第一能量施加装置和第二能量施加装置以粘合复合纤网。

Description

利用具有砧图案的旋转粘合系统形成复合纤网的方法
背景技术
使用超声形成非织造物并且提供压印图案的热粘合是本领域技术人员熟知的。例如，超声粘合已经被用于制造一次性类型服装诸如尿布、训练裤、女性用品、失禁服装，并且特别地用于形成这些类型制品的侧缝。
吸收制品的设计需要这些粘合符合某些物理要求以按预期执行。已经表明，相比于例如具有等效表面积的点图案，其中条垂直于产品边缘取向的矩形条图案产生最高粘合强度和最大断裂伸长率，从而产生根据预期工作和起作用的产品。
然而，垂直于产品边缘取向的条的图案给旋转粘合系统带来了某些操作问题。例如，当超声焊头压贴砧并且平行于砧轴线移动时，由于凸起的粘合图案从砧表面突出，超声焊头和砧之间的接触面积根据焊头沿着砧的位置发生变化。因此，仅包括垂直于砧轴线取向的一系列条的图案意味着焊头在沿着砧滚动时在接触区域中经受中断。焊头与砧之间的接触中断可以激发砧、砧支撑件和焊头支撑结构中的结构谐振，从而导致粘合强度可变性和超声发生器过载。该问题最终导致浪费和生产率损失。
因此，需要开发一种超声粘合系统和方法，其能够提供在粘合中包括必需强度的粘合的复合纤网，同时消除由粘合系统内的不稳定性引起的浪费。
发明内容
在一个实施方案中，本文公开了一种将第一材料纤网粘合到第二材料纤网以形成复合材料的方法。首先，提供在机器方向上移动的第一材料纤网和第二材料纤网。材料纤网通过在横跨机器方向上横向延伸的第一能量施加装置。第一能量施加装置包括主粘合图案和辅粘合图案。主粘合图案结合辅粘合图案在横跨机器方向上连续延伸横跨第一能量施加装置。另外，提供了第二能量施加装置。第二能量施加装置在横跨机器方向上移动，且由此在第一能量施加装置上方延伸第二能量施加装置，并且组合操作第一能量施加装置和第二能量施加装置。能量由此在横跨第一材料纤网和第二材料纤网逐渐移动的线处施加于第一材料纤网和第二材料纤网，以将第一材料纤网粘合到第二材料纤网并且形成复合材料。
在一个实施方案中，本文公开了一种将第一材料纤网粘合到第二材料纤网以形成复合材料的方法。首先，提供在机器方向上移动的第一材料纤网和第二材料纤网。材料纤网通过在横跨机器方向上横向延伸的第一能量施加装置。第一能量施加装置包括主粘合图案和辅粘合图案。另外，提供了第二能量施加装置。第二能量施加装置在横跨机器方向上移动，且由此在第一能量施加装置上方延伸第二能量施加装置，并且组合操作第一能量施加装置和第二能量施加装置。能量由此在横跨第一材料纤网和第二材料纤网逐渐移动的线处施加于第一材料纤网和第二材料纤网，以将第一材料纤网粘合到第二材料纤网并且形成复合材料。在操作期间，主粘合图案在横跨机器方向上提供第一能量施加装置与第二能量施加装置之间的非连续接触，并且辅粘合图案在横跨机器方向上提供第一能量施加装置与第二能量施加装置之间的连续接触。
在示例性实施方案中，第一能量施加装置包括砧，第二能量施加装置包括旋转超声焊头。在操作期间，能量可仅通过主粘合图案施加到第一材料纤网和第二材料纤网。当组合操作第一能量施加和第二能量施加时，辅粘合图案为辅能量施加装置提供支撑。在该实施方案中，辅粘合图案不向第一材料纤网和第二材料纤网提供能量。
在一些实施方案中，辅粘合图案在横跨机器方向上是不连续的，从而防止在粘合期间切断复合物。这允许在将第一材料纤网粘合到第二材料纤网之后保持纤网用于进一步处理复合材料。
在另一个示例性实施方案中，主粘合图案包括在机器方向上延伸的至少一排离散条，其中离散条在横跨机器方向上间隔开。在该实施方案中，辅粘合图案在离散条间隔开的位置处为第二能量施加装置提供支撑。有利地，主粘合图案包括在机器方向上延伸的两排离散条，其中离散条在横跨机器方向上间隔开。
辅粘合图案可具有若干种不同设计。例如，辅粘合图案包括与机器方向成一定角度延伸的离散条。在另一个实例中，辅粘合图案包括在横跨机器方向上延伸横跨第一能量施加装置的一系列圆形元件。
附图说明
呈现给本领域普通技术人员的本发明的完整且能够实现的公开内容在说明书的剩余部分中参照附图更具体地阐述，在附图中：
图1是用于将两种材料粘合在一起的超声粘合系统的示例性实施方案的顶部侧透视图，示出了砧和旋转超声焊头。
图2是图1的超声粘合系统的示例性实施方案的特写顶部侧透视图。
图3是用于图1的超声粘合系统内的图案的顶视图。
图4是用于图1的超声粘合系统内的替代图案的顶视图。
图5是用于图1的超声粘合系统内的替代图案的顶视图。
图6是用于图1的超声粘合系统内的替代图案的顶视图。
图7是用于图1的超声粘合系统内的替代图案的顶视图。
图8A示出了利用图1的超声粘合系统制造的示例性复合纤网和用于图3的系统的图案。
图8B示出了图8A所示的复合纤网的横剖视图。
图8C示出了在切割复合纤网之后图8A所示的复合纤网的横剖视图。
图8D示出了图8A所示的复合纤网的横剖视图。
在本说明书和附图中重复使用附图标记旨在表示本公开的相同或类似的特征或元件。
具体实施方式
图1示出了本文所述的粘合系统10的一个实施方案。粘合系统10可包括通过其传递的热能足以将材料焊接在一起的任何装置，诸如电阻装置如连续加热或间歇加热的脉冲型装置、压力或感应加热部件。有利地，通过使用超声能量提供热能源。
超声粘合系统10可用于制造一次性类型服装诸如尿布、训练裤、女性用品、失禁服装等，并且包括通过在间隔开的位置产生超声粘合接合两个叠置的复合纤网的方法，所述间隔开的位置在横向于纤网在处理设备中的行进方向(机器方向)的方向(横跨机器方向)上延伸横跨纤网。有利地，在连续结合的纤网中生产一次性类型服装，其中纤网中的服装横向于纤网延伸，服装的腰部部分沿着纤网的机器方向延伸，并且服装的前部和后部位于纤网的相对侧上。在所示的实施方案中，粘合在大致对应于成品服装中侧缝的最终位置的位置处接合两个材料纤网。
在使用已知技术形成这种粘合时，难以在整个纤网宽度上获得均匀的热能施加，由此粘合可能表现出低于期望的均匀性。本文公开的设备和方法提供了一种新颖的方法，以实现可预测均匀性的粘合强度。
如图1所示，本文公开了将第一材料纤网12粘合到第二材料纤网14并形成复合材料16的超声粘合系统10。首先，提供在机器方向32上移动的第一材料纤网12和第二材料纤网14。材料纤网12、14通过沿横跨机器方向30延伸的第一能量施加装置18。另外，提供了第二能量施加装置20。通过沿方向40旋转，第二能量施加装置20在横跨机器方向30上移动，且由此在第一能量施加装置18上方延伸第二能量施加装置20，并且组合操作第一能量施加装置18和第二能量施加装置20。能量，优选地超声能量，由此在横跨第一材料纤网12和第二材料纤网14逐渐移动的线处施加于第一材料纤网12和第二材料纤网14，以将第一材料纤网粘合到第二材料纤网并且形成复合材料16。
在一个示例性的超声粘合系统10中，第一能量施加装置18是砧22，并且第二能量施加装置20包括超声焊头24。在另选实施方案中，第一能量施加装置18是超声焊头24，并且第二能量施加装置20包括砧22。砧22可包括在横跨机器方向30上延伸的金属条。
超声焊头24优选地安装成在砧22上方延伸，以在位于砧22上时向材料纤网12、14施加向下压力，由此当在砧22上方延伸时向材料纤网12、14施加超声能量，并且随后从砧22上退出。超声焊头24可以安装成在砧和砧22上的材料纤网12、14上方横穿能量施加路径35，能量施加路径35在横跨材料纤网12、14的横跨机器方向30上取向。超声粘合系统10优选地还包括用于通过超声焊头24将压力和超声能量两者同时施加到布置在砧上的材料纤网12、14的方法，由此在超声焊头24通过砧22上的材料纤网12、14上方时压力粘合材料纤网12、14。
优选地，如图1所示，超声焊头24包括轮26，因此是旋转超声焊头，其被安装成围绕第二轴线旋转，随着超声焊头24横穿能量施加路径35，在横跨机器方向30上移动横跨材料纤网，由此将超声能量施加到材料纤网12、14上。能量施加路径35可以包括其中旋转超声焊头24在砧上方延伸的离开区段，以及其中旋转超声焊头从砧上方退出的进入区段，随着超声焊头24横穿能量施加路径35，超声系统进一步通过旋转超声焊头24向材料纤网12、14施加压力，由此通过旋转超声焊头24将压力施加到能量施加路径35的一个区段(优选地离开区段)上的材料纤网12、14，并且抑制能量施加路径35的另一个区段上的压力。
在一些实施方案中，超声粘合系统10还可包括安装在围绕滚筒的外部工作表面的不同径向位置处的至少两个超声焊头，以及安装成与滚筒一起旋转并且位于所述至少两个超声焊头中的相应一个上方的对应的至少两个砧，优选地旋转砧。这种超声粘合系统的实例可以在授予Rajala等人的美国专利No.5,667,608中找到，该专利通过引用方式并入本文。
通常，能量施加装置20中的一个具有大体平滑的外圆周表面26，而另一能量施加装置18包括凸起的粘合突出部的主图案60和辅图案62，其在设计和位置上对应于图3至图7中反映的粘合图案。在所示的实施方案中，砧22包括主粘合图案60和从砧的基部表面64延伸的辅粘合图案62。
各个突出部从第一能量施加装置18上的基部表面64延伸。突出部在远端表面处终止，该远端表面负责产生相应的粘合元件54。通常，这样的突出部可以例如最多约0.10英寸高，并且最多约0.06英寸宽。高度被限定为从辊的基部圆周表面到远侧末端或平台的突出部的尺寸，所述远侧末端或平台实际上与例如其中形成粘合的纤网材料相接触。
主粘合图案60和辅粘合图案64以及各个粘合元件54可通过多种方法激活，包括但不限于施加压力、热能和压力或超声能量和压力，以将两个材料纤网粘合在一起。有利地，当采用超声能量时，适当调节例如砧辊20的尺寸，如本领域已知的，从而不会有害地干扰超声焊头15的谐振频率。
返回参考图1和图2，第一能量施加装置18包括主粘合图案60和辅粘合图案62。主粘合图案60结合辅粘合图案62在横跨机器方向30上连续延伸横跨第一能量施加装置18。有利地，在操作期间，主粘合图案60在横跨机器方向30上提供非连续接触，并且辅粘合图案62在横跨机器方向30上提供连续接触。
在一个实施方案中，随着材料纤网12、14穿过超声粘合系统10，能量在纤网上对应于相应突出部或粘合元件54、56的位置处施加到纤网12、14，由此将两个纤网材料粘合在一起以形成复合纤网。在另一个实施方案中，随着材料纤网12、14穿过超声粘合系统10，能量仅在纤网上对应于主粘合图案60上的相应突出部54的位置处施加到纤网，由此将两个纤网材料12、14粘合在一起以形成复合纤网16。在该实施方案中，辅粘合图案62在超声焊头24通过砧22和材料纤网12、14时充当超声焊头的支撑。
主粘合图案60包括主粘合面积，其被限定为主粘合图案元件54的远端表面之一的总面积。辅粘合图案62包括辅粘合面积，其被限定为辅粘合图案元件56的远端表面之一的总面积。有利地，主粘合面积大于辅粘合面积。在期望的实施方案中，辅粘合面积介于主粘合面积的约10％至约49％之间。
图3示出了砧22的一个期望实施方案，示出了凸起粘合元件54的主粘合图案60和凸起粘合元件56的辅粘合图案62。主粘合图案60包括在机器方向32上延伸的至少一排68离散条。在该实施方案中，主粘合图案60包括在机器方向32上延伸的两排68、70离散条，其在横跨机器方向30上间隔开，两排68、70沿着砧22的两个边缘延伸。该主粘合图案60被构造成当服装垂直于粘合轴线应变时允许复合材料的最大颈缩和伸长率。
在该实施方案中，辅粘合图案62位于主粘合图案60内的两排68、70离散条之间，并且包括在横跨机器方向30和机器方向32两者上延伸的一排72离散条。
辅粘合图案62的离散条是间隔开的，有利地使辅粘合图案62在横跨机器方向30上是不连续的，从而防止在粘合期间切断复合物16。这允许在纤网16继续向下沿着生产线前进时进一步对其进行处理。值得注意的是，主粘合图案60和辅粘合图案62在结合时在能量路径位置35的整个长度上延伸，以确保在操作期间将超声焊头24支撑在砧22上。另外，虽然不是连续的，调节辅粘合图案62内的离散条的角度导致在能量施加路径35上操作期间的连续接触，并且确保超声焊头24的支撑。
除了更好的粘合强度一致性之外，在操作期间支撑超声焊头24的显著益处是降低功率反馈尖峰。反馈尖峰由砧与旋转超声焊头之间的常规粘合图案的接触变化的特性引起。与相应的平均复合接触长度相比，常规粘合图案倾向于表现出复合接触长度的较大变化。复合接触长度的变化导致常规粘合图案的功率分布的对应并且通常是成比例的变化。这种变化是例如限定排和线(彼此垂直)的矩形布置的粘合图案的结果，并且是沿着粘合图案的长度并且垂直横跨该长度延伸的点的结果。因此，对于每个横向排的点，这种常规图案的复合接触长度从排在辊隙中时的最大接触长度变化到排之间的零或接近零的长度，由此在每排的点/圆点/圆处产生对应的功率尖峰极限，由此这种砧辊的有效直径在连续的横向排的点之间略微变化，并且其中每个这种变化都有助于辊隙处焊头和砧的振动。
通过结合在能量路径35的整个长度上延伸的主粘合图案60和辅粘合图案62，粘合系统的操作确保了在本文描述的操作期间将超声焊头24支撑在砧22上，从而降低功率尖峰，并且为该过程创造更高稳定性。这降低了复合纤网中的粘合可变性，增加了材料的伸长率和粘合强度。
图4示出了砧22的另一个期望实施方案，示出了凸起粘合元件54的主粘合图案60和凸起粘合元件56的辅粘合图案62。类似于图3，主粘合图案包括在机器方向32上延伸的两排68、70离散条，所述离散条在横跨机器方向30上间隔开。在该实施方案中，辅粘合图案62放置在主粘合图案60内的两排68、70离散条之间，并且包括在横跨机器方向30上延伸的至少一排62离散圆形元件75。辅粘合图案62的离散条是间隔开的，有利地使辅粘合图案62在横跨机器方向30上是不连续的，从而防止在粘合期间切断复合物。类似地，该实施方案的主粘合图案60和辅粘合图案62在结合时在能量路径位置35的整个长度上延伸，以确保在操作期间将超声焊头24支撑在砧22上。
图5示出了砧22的另一个期望实施方案，示出了凸起粘合元件54的主粘合图案60和凸起粘合元件56的辅粘合图案62。类似于图3，主粘合图案60包括在机器方向32上延伸的两排68、70离散条，所述离散条在横跨机器方向上间隔开。在该实施方案中，辅粘合图案62置于主粘合图案60内的两排68、70离散条之间，并且包括在横跨机器方向30和机器方向32两者上延伸的一排离散条。另外，辅粘合图案62的离散条可具有形成在内部的间隙74，以使辅粘合图案62在横跨机器方向30上是不连续的，从而防止在粘合期间切断复合物。
图6示出了砧22的另一个期望实施方案，示出了凸起粘合元件54的主粘合图案60和凸起粘合元件56的辅粘合图案62。类似于图3，主粘合图案包括在机器方向32上延伸的两排68、70离散条，所述离散条在横跨机器方向上间隔开。在该实施方案中，辅粘合图案62置于主粘合图案60内的两排68、70离散条之间，并且包括在横跨机器方向30和机器方向32两者上延伸的人字形图案76的条。另外，辅粘合图案62的人字形图案76可具有形成在内部的间隙74，以使辅粘合图案62在横跨机器方向30上是不连续的，从而防止在粘合期间切断复合物。
图7示出了砧22的另一个期望实施方案，示出了凸起粘合元件54的主粘合图案60和凸起粘合元件56的辅粘合图案62。类似于图3，主粘合图案60包括在机器方向32上延伸的两排68、70离散条，其在横跨机器方向上间隔开。在该实施方案中，辅粘合图案62被置于主粘合图案60内的两排68、70之间，并且包括在机器方向32上邻近主粘合图案60延伸的单排材料78。另外，辅粘合图案62的单排材料78可具有形成在内部的间隙74，以使辅粘合图案62在横跨机器方向30上是不连续的，从而防止在粘合期间切断复合物。这种设计允许主粘合图案60和辅粘合图案62在结合时在能量路径位置35的整个长度上延伸，以确保在操作期间将超声焊头24支撑在砧上。
图3至图7中描述的图案旨在与如授予Rajala等人的美国专利No.5,667,608中所述的旋转超声系统一起使用，其中在操作期间超声焊头沿着砧表面滚动，这与其中在粘合期间焊头与砧之间不存在相对运动的活塞型超声粘合相反。这里描述的砧图案60、62在焊头24沿着砧22滚动时为其提供连续支撑，这将粘合强度可变性和发生器过载两者降至最低，从而导致较低的粘合强度可变性和更大的生产率。
超声粘合系统10可用于制造一次性类型服装诸如尿布、训练裤、女性用品、失禁服装等。超声粘合系统可用于在连续结合的纤网中生产一次性类型服装，其中纤网中的服装横向于纤网延伸，服装的腰部部分沿着纤网的机器方向延伸，并且服装的前部和后部位于纤网的相对侧上。在所示的实施方案中，粘合在大致对应于成品服装中侧缝的最终位置的位置处接合第一材料纤网和第二材料纤网。
如图8A至图8D所示，通过结合第一材料纤网12和第二材料纤网14并利用图3所示的主粘合图案60和辅粘合图案62从而由超声粘合系统10形成复合纤网16。图8A示出了复合纤网16的顶视图，其示出了复合纤网16内所得的主粘合图案82和辅粘合图案84。由于通过辅粘合图案施加的粘合能量不到总粘合能量的一半，因此当复合纤网16垂直于粘合轴线应变时，辅粘合图案84对侧缝粘合强度没有贡献，并且不抑制服装材料的横跨机器方向颈缩。图8B和图8C示出了在切割线86处切割材料之前和之后的复合材料16的横剖视图，该材料位于与材料内的辅粘合图案相对应的主粘合图案之间。一旦切割后，复合纤网16即切割成两个产品90、92，并且如图所示代表吸收制品的侧面板。主粘合图案82产生凸缘侧缝94，其具有消费者使用产品90、92所需的粘合强度。
在“具体实施方式”中引用的所有文件在相关的部分中均以引用方式并入本文；对任何文件的引用均不应被解释为承认其是关于本发明的现有技术。在本书面文件中的术语的任何含义或定义与以引用方式并入的文件中的术语的任何含义或定义冲突的情况下，应当以赋予本书面文件中的术语的含义或定义为准。
虽然已经示出并描述了本发明的特定实施方案，但对本领域的技术人员将显而易见的是，在不背离本发明的精神和范围的情况下可以作出各种其他变化和修改。因此，在所附权利要求书中意图涵盖所有在本发明范围内的这样的变化和修改。

Claims (26)

1.一种将第一材料纤网粘合到第二材料纤网以形成复合材料的方法，所述方法包括以下步骤：
(a)提供在机器方向上移动的第一材料纤网和第二材料纤网；
(b)提供在横跨机器方向上横向延伸的第一能量施加装置，所述第一能量施加装置包括主粘合图案和辅粘合图案，其中所述主粘合图案结合所述辅粘合图案在所述横跨机器方向上连续延伸；
(c)提供第二能量施加装置；并且
(d)在所述横跨机器方向上移动所述第二能量施加装置，且由此在所述第一能量施加装置上方延伸所述第二能量施加装置，并且组合操作所述第一能量施加装置和第二能量施加装置，且由此在横跨所述第一材料纤网和第二材料纤网逐渐移动的线处向所述第一材料纤网和所述第二材料纤网施加能量，以将所述第一材料纤网粘合到所述第二材料纤网。
2.根据权利要求1所述的方法，其中所述第一能量施加装置包括砧，所述第二能量施加装置包括旋转超声焊头。
3.根据权利要求1所述的方法，其中组合操作所述第一能量施加装置和第二能量施加装置，且由此仅通过所述主粘合图案向所述第一材料纤网和所述第二材料纤网施加能量。
4.根据权利要求1所述的方法，其中当组合操作所述第一能量施加和第二能量施加时，所述辅粘合图案为所述辅能量施加装置提供支撑。
5.根据权利要求4所述的方法，其中所述辅粘合图案不向所述第一材料纤网和所述第二材料纤网提供能量。
6.根据权利要求1所述的方法，其中所述辅粘合图案在所述横跨机器方向上是非连续的。
7.根据权利要求1所述的方法，其中所述主粘合图案包括在所述机器方向上延伸的至少一排离散条，其中所述离散条在所述横跨机器方向上间隔开，其中所述辅粘合图案在所述离散条间隔开的位置处提供支撑。
8.根据权利要求7所述的方法，其中所述主粘合图案包括在所述机器方向上延伸的两排离散条，其中所述离散条在所述横跨机器方向上间隔开。
9.根据权利要求1所述的方法，其中所述辅粘合图案包括与所述机器方向成一定角度延伸的离散条。
10.根据权利要求1所述的方法，其中所述辅粘合图案包括在所述横跨机器方向上延伸横跨所述第一能量施加装置的一系列圆形元件。
11.根据权利要求1所述的方法，还包括在将所述第一材料纤网粘合到所述第二材料纤网之后保持所述纤网用于进一步处理。
12.根据权利要求1所述的方法，其中所述主粘合图案包括主粘合面积，并且所述辅粘合图案包括辅粘合面积，其中所述辅粘合面积介于所述主粘合面积的约10％和约49％之间。
13.根据权利要求1所述的方法，还包括当组合操作所述第一能量施加装置和第二能量施加装置时施加压力。
14.一种将第一材料纤网粘合到第二材料纤网的方法，所述方法包括以下步骤：
(a)提供在机器方向上移动的第一材料纤网和第二材料纤网；
(b)提供在横跨机器方向上横向延伸的第一能量施加装置，所述第一能量施加装置包括主粘合图案和辅粘合图案；
(c)提供第二能量施加装置；并且
(d)在所述横跨机器方向上移动所述第二能量施加装置，且由此在所述第一能量施加装置上方延伸所述第二能量施加装置，并且组合操作所述第一能量施加装置和第二能量施加装置，且由此在横跨所述第一材料纤网和第二材料纤网逐渐移动的线处向所述第一材料纤网和所述第二材料纤网施加能量以形成复合材料，其中所述主粘合图案在所述横跨机器方向上提供所述第一能量施加装置与所述第二能量施加装置之间的非连续接触，并且所述辅粘合图案在所述横跨机器方向上提供所述第一能量施加装置与所述第二能量施加装置之间的连续接触。
15.根据权利要求14所述的方法，其中所述第一能量施加装置包括砧，并且所述第二能量施加装置包括旋转超声焊头。
16.根据权利要求14所述的方法，其中组合操作所述第一能量施加装置和第二能量施加装置，且由此仅通过所述主粘合图案向所述第一材料纤网和所述第二材料纤网施加能量。
17.根据权利要求14所述的方法，其中当组合操作所述第一能量施加和第二能量施加时，所述辅粘合图案为所述辅能量施加装置提供支撑。
18.根据权利要求14所述的方法，其中所述辅粘合图案不向所述第一材料纤网和所述第二材料纤网提供能量。
19.根据权利要求14所述的方法，其中所述辅粘合图案在所述横跨机器方向上是非连续的。
20.根据权利要求14所述的方法，其中所述主粘合图案包括在所述机器方向上延伸的至少一排离散条，其中所述离散条在所述横跨机器方向上间隔开，其中所述辅粘合图案在所述离散条间隔开的位置处提供支撑。
21.根据权利要求20所述的方法，其中所述主粘合图案包括在所述机器方向上延伸的两排离散条，其中所述离散条在所述横跨机器方向上间隔开。
22.根据权利要求14所述的方法，其中所述辅粘合图案包括与所述机器方向成一定角度延伸的离散条。
23.根据权利要求14所述的方法，其中所述辅粘合图案包括在所述横跨机器方向上延伸横跨所述第一能量施加装置的一系列圆形元件。
24.根据权利要求14所述的方法，还包括在将所述第一材料纤网粘合到所述第二材料纤网之后保持所述纤网用于进一步处理。
25.根据权利要求14所述的方法，其中所述主粘合图案包括主粘合面积，并且所述辅粘合图案包括辅粘合面积，其中所述辅粘合面积介于所述主粘合面积的约10％和约49％之间。
26.根据权利要求14所述的方法，还包括当组合操作所述第一能量施加装置和第二能量施加装置时施加压力。
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