CN1099484C - 制造具有某种结构的大量无纺织物的压印方法和第二辊对 - Google Patents

制造具有某种结构的大量无纺织物的压印方法和第二辊对 Download PDF

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CN1099484C
CN1099484C CN98806361A CN98806361A CN1099484C CN 1099484 C CN1099484 C CN 1099484C CN 98806361 A CN98806361 A CN 98806361A CN 98806361 A CN98806361 A CN 98806361A CN 1099484 C CN1099484 C CN 1099484C
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pimple
woven fabric
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沃纳·瓦格纳
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HCD Hygienic Composites Development GmbH
Fiberweb Corovin GmbH
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Abstract

本发明涉及一种制造具有某种结构的大量的无纺织物的方法，包括下列工艺步骤：由许多单丝制成纺粘型无纺织物，单丝只是在最大可能伸张量50至70%范围内伸张并铺叠成纤维条子，以及，通过第二辊对(10a、b)对无纺坯布进行再处理以改善起绒整理，其中，辊的外套用金属制造，其中阳辊的阳体是排列成行的疙瘩(11)以及阴辊的表面有沿轴向排列的齿片(13)和位于齿片之间的凹槽(14)，所以在辊相对滚压时齿片插入疙瘩留出的小通道中。

Description

制造具有某种结构的大量无纺织物的压印方法和第二辊对
本发明涉及一种制造具有某种结构的大量无纺织物的方法，包括下列工艺步骤：
(a)由许多单丝制成纺粘型无纺织物，单丝只是在最大可能伸张量50至70％范围内伸张并铺叠成纤维条子，
(b)通过第一辊对将纤维条子挤压和熔接成无纺坯布，
(c)无纺坯布通过第二辊对再处理，其中至少一个辊的外套由金属制成，第二辊对由一个具有许多沿辊外表面分布的阳体的阳辊和一个同样有许多个的凹槽的阴辊组成，在轧制过程中，阳体插入凹槽内以及无纺坯布在辊啮合区内再次伸张。
本发明还涉及一种制造具有某种结构的大量无纺织物的第二辊对。
上述在原始申请DE 195 17 319中所述的方法以按照US-PS5399174的先有技术为出发点。在此美国专利文件中介绍了一种层状薄片，其中，由卷曲的聚合束纤维构成并粘合有聚合薄膜层的无纺织物层借助于辊压印，使之形成连接和装饰花纹，花纹使无纺织物与薄膜连接。在上述美国专利的说明书背景技术部分中还提及，滚花是一种工艺方式，用于改变无纺织物的密着性，与此同时产生一种装饰性设计。尤其可参见美国专利文件4592942，其中采用了一种工艺，当要加工的无纺织物薄片在两个格网之间移动时加热此无纺织物，所以格网确定的形状给予无纺织物使之相应地成形。此外可参见美国专利4774124，它公开了一种花式轧制压印工艺。
此外由US-PS 5356364还已知一种压印工艺，其中两个辊不完全一致(“unmatched”)的阳体和阴体可以实施一种压印过程，它应能产生特殊的起绒和压印结构。
上述这些工艺方法的共同点是，从一开始必须制造大量的无纺织物层，然后借助于压印工艺制成花纹。但无纺织物层的体积不增加。
建立在德国专利申请DE 19547319的理论的基础上，本发明的目的是，使一种纺粘型无纺织物，它已经铺叠并按照无纺织物工艺有已经部分粘合的纤维和长丝，履行规定的体积增大。
为实现上述目的，按本发明的一个方面，提供了这样一种开头所述类型的制造具有某种结构的大量的无纺织物的方法，其特征在于采用的第二辊对，其中辊的外套用金属制造，其中阳辊的阳体有排列成行的疙瘩以及阴辊的表面有沿轴向排列的齿片和位于齿片之间的凹槽，因此在辊相对滚压时齿片插入疙瘩留出的小通道中，这时，无纺织物被局部保持，并可直接在旁边被伸长。
最好是两个辊用一种相同的洛氏硬度(HRC)大于50的金属。通过沿多个疙瘩间距延伸的沿轴向排列的齿片，在70％的预伸张情况下可以改善伸张，尤其是获得一种特殊的结构，这种结构在疙瘩顶端处开口并在专业术语中称为“开口的无纺织物”。
这些开口按照金属疙瘩的几何形状形成某种结构。根据疙瘩的周边可获得一种较大的无纺织物开口和穿孔。在这里，这些开口显示了一种向无纺织物背面外突的造型。朝使用侧开口起如同细小的漏斗的作用，它也承接液体和继续传输。对于一种包覆材料希望有这种效果，因为可以吸收液体并排出。通过使无纺织物有三维结构，防止液体重新回到表面上。这些表面保持干燥。除此以外，无纺织物的外侧给人们一种柔软、纺织和弹性的手感。
借助于第二辊对可基本上确定成品的起绒整理和结构。因此建议，第二辊对辊间距并因而辊彼此的侵入可以调整。最好采用疙瘩高度在0.8与2mm之间的辊，其中，在100cm2辊表面上的疙瘩数量在2000和3000个之间。
辊的温度也有重要意义。例如阴辊工作时具有比阳辊低的温度。例如阳辊的温度在175℃和190℃之间，阴辊的温度只是在40°和80℃之间。
为了获得无纺织物漏斗状的结构，建议，疙瘩在一顶端处结束，其中，顶端例如是葱头形尖塔状的，也就是说是修圆的和有控制地结束在一个尖端处。但也可以使顶端结束在一个具有锥角为90±20°的角锥体内。
作为制造无纺织物的原材料最好采用聚乙烯、聚丙烯、聚酯或聚酰胺，因为这些热塑性塑料特别清楚地显示有所期望的起绒。
普通的工艺适用于作为制造无纺织物的工艺方法；作为无纺织物例如采用那些按梳理工艺、按气流成网工艺或按熔喷法制造的无纺织物。
在第二次伸张过程中无纺坯布最好侧面紧绷地固定在辊的边缘上，所以它不会收缩。在第二次伸张期间，也就是在无纺坯布第一次通过第二辊对期间，将它保持在一个温度下，这一温度基本上等于在第一次伸张时所处的温度。因此辊的温度大体保持在此温度之上和之下。
为实现上述目的，按本发明的另一方面，还提供了一种由无纺坯布制造具有某种结构的大量的无纺织物的第二辊对，上述无纺坯布是利用一个第二辊对挤压和熔接纤维条子制成的，第二辊对具有一个具有许多沿辊外表面分布的阳体的阳辊和一个同样有许多个的凹槽的阴辊组成，在轧制过程中，阳体插入凹槽内以及无纺坯布在辊啮合区内再次伸张，其特征为：在第二辊对中，辊的外套用金属制造，其中阳辊的阳体是排列成行的疙瘩以及阴辊的表面有沿轴向排列的齿片和在齿片之间的凹槽，所以在辊彼此滚压时齿片插入被疙瘩留出的小通道中。
下面借助于附图表示的举例说明本发明的实施例。附图表示：
图1适用于此方法的设备示意图；
图2a伸张型辊的实施形式详图；
图2b图2a所示伸张型辊实施形式另一个详图；
图3按本方法制成的产品放大透视俯视图。
图1示意表示具有某种结构的大量无纺织物的制造过程。料仓1内有热塑性塑料的颗粒材料，例如由可加工成其无纺织物的聚乙烯、聚酯、聚丙烯或聚酰胺之一制成的粒状体。粒状体到达一个可加热的挤压机内并被挤压螺杆2＇一直推进到挤压机的喷管3。接着，压出物通过导鼻4输入喷丝头5。分配成最细丝的纺丝进入伸张装置18内并接着进入骤冷鼓风机22的区域内，骤冷鼓风机使伸张后的纺丝6冷却。
在伸张装置18内单根纤维不完全伸张。有利的是，聚乙烯和聚丙烯的伸张度仅60至70％，聚酯或聚酰胺仅50至70％。这与一向流行的伸张状况不同，为了节省材料它们实施尽可能完全的伸张过程。
经伸张的纺丝6放在网状传送带7上，传送带下面有一直空架8，所以纺丝平铺在网状传送带7上。然后纺丝在第一辊对，亦即轧光辊9a和9b之间受压缩。经这样处理后得到无纺坯布12；它还有单位面积重量约为20g/m2以及只有几毫米厚。
如此构成的无纺坯布12在轧光辊9a/b内只获得非常松散粘合的无纺织物。只进行了轻度的局部熔化，因为借此使材料易于处理。
现在无纺坯布12供入第二辊对10a、10b，它由两个伸张型辊构成。辊10a是一个具有许多沿辊套表面分布的疙瘩11的阳辊，而阴辊10b同样有许多齿片13和在齿片之间的凹槽14。在轧制过程中疙瘩11插入凹槽14中并使无纺坯布在啮合区内再伸张。
通过这两个辊10a和10b的伸张，使纤维粘合的无纺织物有准确规定的局部过度伸张，因为无纺坯布12固定在边缘上，亦即固定在辊10a/b的外棱边上并因而不可能被向里拉入。因此无纺织物局部固定以及就在固定处的旁边受到极度伸长。取决于辊的结构，也可以取消侧向固定。
如图2a和2b所示，伸张型辊10a和10b的外套设计为，使凸起的部分亦即疙瘩11挺进到相配辊10b的齿片13之间的空腔14内，而压印工具的平的区域固定住有伸张能力的无纺织物的一部分。辊和相配辊彼此准确调整。疙瘩11设计为钝的角锥体。它们也可以修圆和削尖。尤其适合的是一种其顶端葱头形尖塔状结束的造型。
薄片的宽度只有疙瘩自由距离的约1/3至1/5。在此实施例中薄片沿整个辊长延伸。但它们也可以较短和不连续。不过薄片长度总是跨接大量的疙瘩间距，而且至少有三个疙瘩间距。
辊10a设有钢制外套或外层。疙瘩11也用钢制成。辊10b的外套同样是钢制的。可使用洛氏硬度为62的钢(参见MessmethodenKLINGELNBERG，Technisches Hilfsbuch，Springer出版社1967第15版)。
从辊10a/b出来的无纺织物15通过局部再伸张不仅在其纤维长度而且在其无纺织物连接方面都产生显著变化。通过相应地设计辊，无纺坯布获得了一种如图3所示的具有三维特征的结构，这在下面还要说明。
单根纤维在伸展区成为高强度的，所以体积特性也能耐久。整个无纺织物的手感更柔软和更有弹性，并显示出一种改变了的输水矢量。水份沿高质量的连续纤维从表面向无纺织物背面输送。
第二辊对的辊间距并因而辊彼此的入侵，如由轧制技术已知的那样可以相对调整。在此实施例的情况下疙瘩的高度约为1.5mm，疙瘩彼此的间距约为1.5mm。疙瘩的数量为每100cm2 2500个。它例如用于制造一种由纺粘型无纺织物构成的包覆料，其中按相同的工序将密度为每cm2 7g的聚丙烯纤维排放在传送带上，并在相同的过程中铺上一层其量为每cm3 2×3g的熔喷法聚丙烯无纺织物，以及此整体用另一层每cm27g的聚丙烯纺粘型无纺织物覆盖。此复合体首先输入轧制设备并点状连接。然后，这种以聚丙烯为基础预粘合的纺粘型无纺织物输入第二辊对，并在疙瘩辊温度为175℃以及薄片辊温度为80℃的情况下穿孔和变形。
图3表示了一种成型材料，它每厘米约有五个由疙瘩形成的漏斗形凹穴20，在凹穴之间留有平面21。无纺织物的高度也就是指“斗”的深度约为1mm。这种材料在疙瘩区内的底部穿孔并完全显示出来，因此在卫生领域可例如用作生产尿布时的包覆料或在生产妇女卫生制品时用作覆盖层。
在这里导致具有某种结构的疙瘩的形状是具有矩形的平面布置图和锥角为90°的角锥形。所说明的工艺过程也可以在线与制造纺粘型无纺织物一起进行。但无纺坯布也可以单独制造以及后处理。也可以在已膨化的无纺织物上再粘贴第二个无纺织物或薄膜。
类似于原始申请，上述工艺方法在原则上可应用于所有的塑料，如聚乙烯、聚酯、聚丙烯、聚酰胺等，它们适用于具有预伸张的熔融纺丝法。
上述工艺方法原则上适合于使用和加工所有用传统方法生产的无纺织物，这些无纺织物是按梳理工艺、按气流成网工艺或按熔喷法制造的。
按梳理工艺或气流成网工艺由短纤维制造的无纺织物，通过使用短纤维的，亦即将约2至5旦的纤维切为长度约3至6cm的切段纤维的梳理机或梳毛机制造、轻度预压印、然后经受按本发明的变形过程。
在气流成网的无纺织物中短纤维通过空气流输送，并以薄的无纺织物形式排放在网状筒上。此通过压印预连接的无纺织物再经受按本发明的变形过程。
短纤维无纺织物可以变形，因为它们还有足够的剩余伸长能力，这种能力来源于短纤维的可滑移性及其卷曲。梳理和气流成网的无纺织物所使用的单位面积重量为15g/m2至30g/m2，必要时也可使用更大的单位面积重量。
喷熔法无纺织物由聚合物熔体制成，其中将从喷丝头喷出的小滴拉伸成最细的单根纤维。单根纤维被空气流带走并按无纺织物的形式铺叠在传送带上。喷熔法的纤维非常细和软。由于它们没有足够的强度，所以它们往往与其他无纺织物组合。在卫生领域中，为按本发明的工艺方法制造，喷熔法无纺织物可单独地可以与其他无纺织物组合应用。由喷熔法纤维制的具有单位面积重量为10g/m2至20g/m2的无纺织物尤其能良好地变形。

Claims (25)

1.制造具有某种结构的大量的无纺织物的方法，包括下列工艺步骤：
(a)由许多单丝制成纺粘型无纺织物，单丝只是在最大可能伸张量50至70％范围内伸张并铺叠成纤维条子，
(b)通过第一辊对(9a、b)将纤维条子挤压和熔接成无纺坯布(12)，
(c)无纺坯布通过第二辊对(10a、b)再处理，其中至少一个辊的外套由金属制成，第二辊对由一个具有许多沿辊外表面分布的阳体(11)的阳辊(10a)和一个同样有许多个的凹槽(12)的阴辊(10b)组成，在轧制过程中，阳体插入凹槽内以及无纺坯布在辊啮合区内再次伸张，
其特征在于采用的第二辊对(10a、10b)，其中辊的外套用金属制造，其中阳辊的阳体有排列成行的疙瘩(11)以及阴辊的表面有沿轴向排列的齿片(13)和位于齿片之间的凹槽(14)，因此在辊相对滚压时齿片插入疙瘩留出的小通道中，这时，无纺织物被局部保持，并可直接在旁边被伸长。
2.按照权利要求1所述的方法，其特征为：此辊对的辊用基本上硬度相同的金属制造，金属的洛氏硬度(HRC)大于50。
3.按照权利要求1所述的方法，其特征为：调整第二辊对的辊间距并因而调整辊彼此的侵入。
4.按照权利要求1所述的方法，其特征为：疙瘩的高度在0.8和2mm之间。
5.按照权利要求1所述的方法，其特征为：排成一直线的疙瘩彼此的距离在1和2.5mm之间。
6.按照权利要求1所述的方法，其特征为：在100cm2辊表面上的疙瘩数量在2000和3000个之间。
7.按照权利要求1所述的方法，其特征为：第二辊对的辊(10a、10b)的温度调整为不同的大小。
8.按照权利要求7所述的方法，其特征为：阴辊的温度调整为比阳辊的温度至少低20℃。
9.按照权利要求1所述的方法，其特征为：在第二次伸张过程中，无纺坯布保持在一个温度下，这一温度基本上等于在第一次伸张时所处的温度。
10.按照权利要求1所述的方法，其特征为：疙瘩在一顶端处结束。
11.按照权利要求10所述的方法，其特征为：顶端是葱头形尖塔状的。
12.按照权利要求11所述的方法，其特征为：顶端结束在一个锥角为90°±20°的角锥体内。
13.按照权利要求1所述的方法，其特征为：生产无纺织物的原材料采用聚乙烯、聚丙烯或聚酰胺。
14.按照权利要求1所述的方法，其特征为：作为无纺织物采用那些按梳理工艺、按气流成网工艺或按熔喷法制造的无纺织物。
15.按照权利要求1所述的方法，其特征为：在第二次伸张过程中，无纺坯布(12)侧面紧绷地固定在辊的边缘上。
16.按照权利要求1所述的方法，其特征为：在凹槽中进行的第二次伸张导致明显地变薄，必要时直至使无纺坯布在辊啮合区内穿孔。
17.由无纺坯布制造具有某种结构的大量的无纺织物的第二辊对，上述无纺坯布是利用一个第二辊对挤压和熔接纤维条子制成的，第二辊对具有一个具有许多沿辊外表面分布的阳体(11)的阳辊(10a)和一个同样有许多个的凹槽(12)的阴辊(10b)组成，在轧制过程中，阳体(11)插入凹槽(12)内以及无纺坯布在辊啮合区内再次伸张，其特征为：在第二辊对(10a、10b)中，辊的外套用金属制造，其中阳辊的阳体是排列成行的疙瘩以及阴辊的表面有沿轴向排列的齿片和在齿片之间的凹槽，所以在辊彼此滚压时齿片插入被疙瘩留出的小通道中。
18.按照权利要求17所述的辊对，其特征为：辊对的辊用基本上硬度相同的金属制造，金属的洛氏硬度(HRC)大于60。
19.按照权利要求17所述的辊对，其特征为：第二辊对的辊间距并因而辊彼此的侵入是可调的。
20.按照权利要求17所述的辊对，其特征为：疙瘩的高度在0.8和2mm之间。
21.按照权利要求17所述的辊对，其特征为：排成一直线的疙瘩彼此的距离在1和2.5mm之间。
22.按照权利要求17所述的辊对，其特征为：在100cm2辊表面上的疙瘩数量在2000和3000个之间。
23.按照权利要求17所述的辊对，其特征为：疙瘩在一顶端处结束。
24.按照权利要求23所述的辊对，其特征为：顶端是葱头形尖塔状的。
25.按照权利要求24所述的辊对，其特征为：顶端结束在一个锥角为90°±20°的角锥体。
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AU8436598A (en) 1999-01-04
RU2203353C2 (ru) 2003-04-27
CA2294360A1 (en) 1998-12-23
JP2002512660A (ja) 2002-04-23
EP0991803B1 (de) 2001-11-21
ATE209268T1 (de) 2001-12-15
SK284961B6 (sk) 2006-03-02
SK177499A3 (en) 2000-08-14
DE59802744D1 (de) 2002-02-21
BR9810059A (pt) 2000-09-12
RO120492B1 (ro) 2006-02-28
WO1998058109A1 (de) 1998-12-23
PL196582B1 (pl) 2008-01-31
CZ449399A3 (cs) 2000-04-12
PL337619A1 (en) 2000-08-28
AU731831B2 (en) 2001-04-05
HUP0003054A2 (hu) 2001-02-28
CN1260848A (zh) 2000-07-19
CZ300638B6 (cs) 2009-07-08
US6344102B1 (en) 2002-02-05
DE19725749B4 (de) 2004-04-22
DE19725749A1 (de) 1998-12-24

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