CN112022512A

CN112022512A - Composite fiber layer, manufacturing device and manufacturing method thereof, and absorbent article

Info

Publication number: CN112022512A
Application number: CN202010830974.8A
Authority: CN
Inventors: 郝学恩; 翟敏; 吴勇; 庄第
Original assignee: Jiangsu Jinqizhao New Materials Co ltd
Current assignee: Jiangsu Jinqizhao New Materials Co ltd
Priority date: 2020-08-18
Filing date: 2020-08-18
Publication date: 2020-12-04

Abstract

The application relates to a manufacturing device of a composite fiber layer, which comprises a main roller, a first auxiliary roller matched with the main roller, a first fiber layer feeding mechanism, a second auxiliary roller matched with the main roller, a bonding mechanism and a second fiber layer feeding mechanism. The roller surface of the main roller is provided with an embossing piece and an opening piece. The roller surface of the first auxiliary roller is provided with a first hole aligning piece. The first aperture pair is adapted to cooperate with the aperture member to form a first aperture in the first fibrous layer. The first fiber layer feeding mechanism is used for feeding the first fiber layer between the main roller and the first auxiliary roller. The second sub-roller is disposed downstream of the first sub-roller. And embossing counter parts are arranged on the surface of the second auxiliary roller. The embossing pair piece is used for cooperating with the embossing piece to form the embossing surface on the first fiber layer. The bonding mechanism is used for bonding the first fiber layer and the second fiber layer. The second fiber layer feeding mechanism is used for feeding the second fiber layer between the main roller and the bonding mechanism. The present application also relates to a composite fibrous layer, a method of making the same, and an absorbent article.

Description

Composite fiber layer, manufacturing device and manufacturing method thereof, and absorbent article

Technical Field

The invention relates to the technical field of fiber layers, in particular to a composite fiber layer, a manufacturing device and a manufacturing method thereof and an absorbent product.

Background

With the development of personal hygiene articles, there is an increasing demand for breathability and wearing comfort of personal hygiene articles. Currently, such fiber products are classified into single-layer fiber layer products and double-layer fiber layer products according to the number of fiber layers.

In the case of single-ply fibrous layer products, the perforation and embossing of the single-ply fibrous layer take place simultaneously in conventional manufacturing processes. However, the embossed single fiber layer has poor dimensional retention, which affects air permeability and dryness of the finished product, and deteriorates appearance of the product, resulting in a reduction in user experience.

To this end, a double-layered fibrous laminate has been provided in the conventional art to overcome the above-mentioned disadvantages of the single-layered fibrous laminate.

Chinese patent document CN107531009B provides a method for forming a bi-layer laminate, wherein the method uses a conventional two-roller cooperation method to simultaneously perform punching and embossing processes on a first fiber layer, and directly bonds the first fiber layer and a second fiber layer in a subsequent process to form a bi-layer composite fiber layer.

Disclosure of Invention

Exemplary embodiments of the present application provide a composite fiber layer, a manufacturing apparatus, a manufacturing method, and an absorbent article thereof.

An aspect of the present application provides a manufacturing apparatus of a composite fiber layer, including: the main roller is provided with a plurality of embossing pieces and a plurality of perforating pieces on the roller surface; the first auxiliary roll is arranged to be matched with the main roll, a plurality of first hole opening pieces are arranged on the roll surface of the first auxiliary roll, and the first hole opening pieces are used for being matched with the hole opening pieces to form a plurality of first holes in the first fiber layer; a first fiber layer feeding mechanism for feeding the first fiber layer between the main roll and the first sub-roll; the second auxiliary roller is matched with the main roller and arranged at the downstream of the first auxiliary roller, a plurality of embossing pairs are arranged on the roller surface of the second auxiliary roller, and the embossing pairs are used for being matched with the embossing pairs to form a plurality of embossing surfaces on the first fiber layer; the bonding mechanism is used for bonding the first fiber layer and the second fiber layer; and a second fiber layer feeding mechanism for feeding the second fiber layer between the main roller and the bonding mechanism.

In one embodiment, the fit-up gap between the main roller and the first sub-roller is smaller than the fit-up gap between the main roller and the second sub-roller.

In one embodiment, the apparatus further comprises a temperature adjustment device for adjusting the temperature of the roll surface of each roll such that the roll surface temperature of the first sub-roll is greater than or equal to the roll surface temperature of the second sub-roll.

In one embodiment, each of the plurality of perforation members includes at least one perforation pin fixed to a roll surface of the main roll. Each of the plurality of first apertured pairs includes an apertured boss secured to the roll surface of the first companion roll. The surface of the perforated boss, which faces away from the first auxiliary roller, is provided with at least one opening matched with the at least one perforating needle, and the height of the at least one perforating needle is less than or equal to the depth of the at least one matched opening.

In one embodiment, the embossing member includes a plurality of embossing pins and the embossing counter-member includes a corresponding plurality of embossing slots. The outer diameter of the embossing pin is smaller than the inner diameter of the embossing groove, so that the embossing pin can extend into the embossing groove, and the height of the embossing pin is smaller than or equal to the depth of the embossing groove.

In one embodiment, the surface of the embossing pin facing away from the main roller is provided with a central recess. The projection of the central recess onto the surface is located within the surface.

In one embodiment, the bonding mechanism comprises at least one of a thermal bonding apparatus, a glue bonding apparatus, or an ultrasonic bonding apparatus.

In one embodiment, the apparatus further comprises: a third secondary roller which is arranged to be matched with the main roller and is arranged between the first secondary roller and the second secondary roller, wherein a plurality of second hole opening pieces are arranged on the roller surface of the third secondary roller, and the plurality of second hole opening pieces are used for being matched with the plurality of hole opening pieces to form a plurality of second holes on a third fiber layer; and a third fiber layer feeding mechanism for feeding the third fiber layer between the main roller and the third sub-roller. The bonding mechanism is used for bonding the first fiber layer and the third fiber layer with the second fiber layer, and the second fiber layer feeding mechanism is used for feeding the second fiber layer between the main roller and the bonding mechanism so as to be bonded with the first fiber layer and the third fiber layer.

Another aspect of the present application also provides a method of manufacturing a composite fiber layer, including:

providing a device for manufacturing a composite fiber layer according to any one of the above embodiments;

the first fiber layer feeding mechanism feeds the first fiber layer between the main roller and the first sub-roller, and the main roller and the first sub-roller rotate in opposite rotational directions to each other and cooperate with each other to form the plurality of first openings in the first fiber layer;

the main roller positions and conveys the first fiber layer by using the plurality of hole-opening members, and feeds the first fiber layer between the main roller and the second sub-roller, the main roller and the second sub-roller rotate in opposite rotation directions to each other and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer;

the main roller positions and conveys the first fiber layer by the plurality of hole-opening parts, the first fiber layer is conveyed between the main roller and the bonding mechanism, the second fiber layer conveying mechanism conveys the second fiber layer between the main roller and the bonding mechanism, and the bonding mechanism bonds the first fiber layer and the second fiber layer to form a composite fiber layer;

the main roller positions and conveys the composite fiber layer by utilizing the plurality of hole-opening pieces, and sends out the composite fiber layer to roll up the formed cloth.

Yet another aspect of the present application provides a method of manufacturing a composite fiber layer, including:

providing a device for producing the composite fiber layer;

the third fiber layer feeding mechanism feeds the third fiber layer between the main roller and a third sub-roller which rotate in opposite rotational directions to each other and cooperate with each other to form the plurality of second openings in the third fiber layer;

the main roller positions and conveys the third fiber layer by the plurality of opening members and feeds the third fiber layer between the main roller and the first sub-roller, and the first fiber layer feeding mechanism feeds the first fiber layer also between the main roller and the first sub-roller, which rotate in opposite rotational directions to each other and cooperate with each other to form the plurality of first openings in the first fiber layer;

the main roller positions and conveys the first fiber layer and the third fiber layer by using the plurality of perforated members and feeds the first fiber layer and the third fiber layer between the main roller and the second sub roller, the main roller and the second sub roller rotate in opposite rotation directions to each other and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer and the third fiber layer;

the main roller positions and conveys the first fiber layer and the third fiber layer by using the plurality of hole-opening parts, and feeds the first fiber layer and the third fiber layer between the main roller and the bonding mechanism, the second fiber layer feeding mechanism feeds the second fiber layer between the main roller and the bonding mechanism, and the bonding structure bonds the first fiber layer and the third fiber layer with the second fiber layer to form a composite fiber layer;

A further aspect of the present application provides a composite fibre layer formed from the apparatus provided in the above embodiments.

Yet another aspect of the present application provides an absorbent article made at least from the above-described composite fiber layer.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.

FIG. 1 is a schematic structural view of an apparatus for manufacturing a composite fiber layer according to an embodiment of the present disclosure;

FIG. 2 is a schematic structural view of an apparatus for manufacturing a composite fiber layer according to another embodiment of the present application;

FIG. 3A is a schematic view of the engagement of the main roller and the first secondary roller of the embodiment of FIGS. 1 and 2 at A;

FIG. 3B is a schematic view of the engagement of the main and second sub-rolls of the embodiment of FIGS. 1 and 2 at B;

FIG. 3C is a schematic view of the engagement of the main roller and the third secondary roller of the embodiment of FIG. 2 at C;

FIG. 4A is a schematic illustration of a pattern of a composite fiber layer formed by an apparatus according to an embodiment of the present application;

FIG. 4B is a schematic illustration of a pattern of a composite fiber layer formed by an apparatus according to another embodiment of the present application;

FIG. 4C is a schematic illustration of a pattern of a composite fiber layer formed by an apparatus according to yet another embodiment of the present application;

FIG. 4D is a schematic illustration of a pattern of a composite fiber layer formed by an apparatus according to yet another embodiment of the present application;

FIG. 5A is a schematic top view of a two-layer composite fiber layer formed by the manufacturing apparatus shown in FIG. 1;

FIG. 5B is a schematic cross-sectional view of the two-ply composite fiber layer shown in FIG. 5A at line F-F;

FIG. 5C is an enlarged partial view at I of the cross-sectional view shown in FIG. 5B;

FIG. 6A is a schematic top view of a three-ply composite fiber layer formed by the manufacturing apparatus shown in FIG. 2;

FIG. 6B is a schematic cross-sectional view of the three composite fiber layers shown in FIG. 6A at line H-H;

FIG. 6C is an enlarged partial view at II of the schematic cross-sectional view of FIG. 6B;

FIG. 7 is a flow chart of a method of manufacturing a composite fiber layer according to an embodiment of the present application;

fig. 8 is a flow chart of a method of manufacturing a composite fiber layer according to another embodiment of the present application.

Detailed Description

The terms "primary," "secondary," "first," and "second," etc., as used herein, are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicit to any number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature.

Unless expressly defined otherwise, when an element is referred to herein as being "secured to" another element, it can be directly connected to the other element or intervening elements may also be present.

Unless otherwise defined, the terms "upstream" and "downstream" as used herein are used only to describe the relative positioning of the elements in the direction of conveyance of the fibrous layer and are not limiting to the leading or trailing ends of the elements.

As described above, in the conventional technology for manufacturing the composite fiber layer, the conventional two-roller cooperation method is adopted to simultaneously perform the hole opening and embossing processes on the first fiber layer, and directly bond the first fiber layer and the second fiber layer in the subsequent process to form the dual-layer composite fiber layer. However, the inventors have found in practice that, when the composite fiber layer is manufactured by this method, there are the following drawbacks:

1) because the trompil is when being less and need further turn down the fit clearance between two rollers, can produce the mutual interference of impressed watermark cooperation mechanism and trompil cooperation mechanism for the impressed watermark face of fibre layer hardens, leads to final shaping product can form the pit of similar crater after the coiling, feels and comfort level greatly reduced, when serious even, still can take place the trompil needle or the break of knurling round pin.

2) When the fit clearance is enlarged to avoid mutual interference between the opening hole fit mechanism and the embossing fit mechanism, although the softness of the embossing surface can be improved, the adhering of the embossing pin and the fiber layer is not tight, so that the fiber layer falls off from the outer surface of the embossing pin in the conveying process, the adhering position is inaccurate in the subsequent adhering process, the adhered composite fiber layer generates wrinkles, the embossing pattern is damaged or the embossing pattern is not tidy, and the like, and the formed product can generate the phenomenon of inclination or collapse of the embossing pattern after being wound.

3) Since the temperature control affects both the opening quality and the embossing quality, i.e. the opening quality and the embossing quality interfere with each other in the temperature control, when the temperature of the roller needs to be increased to improve the opening quality, the embossing surface is also hardened due to the temperature rise of the roller, and when the temperature control is too small, the opening quality is affected.

Due to the above-mentioned drawbacks of the conventional techniques, the rotation speed of the rolls during the manufacturing process cannot be fast (generally not exceeding 40 m/min), the production yield of the finished product is low (the width of the rolls reaches up to 800 mm), the lifetime of the equipment is not high (generally only about 8 months), and the yield of the finished product is not high (up to about 80%).

Based on this, the inventors found that a better technical solution is urgently needed.

In order to make the objects, technical solutions and advantages of the present application more apparent, the present application is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.

Referring to fig. 1 in conjunction with fig. 3A-3B, fig. 1 is a schematic structural diagram of a manufacturing apparatus of a composite fiber layer according to an embodiment of the present application, fig. 3A is a schematic diagram of a position a of a main roller and a first sub-roller of the embodiment shown in fig. 1, and fig. 3B is a schematic diagram of a position B of the main roller and a second sub-roller of the embodiment shown in fig. 1. The manufacturing apparatus shown in fig. 1 includes a main roll 3, a first sub-roll 2, a first fiber layer feeding mechanism 7, a second sub-roll 4, an ultrasonic bonding mechanism 5, a thermal bonding mechanism 9, and a second fiber layer feeding mechanism 6.

Referring to fig. 1 in conjunction with fig. 3A, a plurality of embossing members 340 and a plurality of perforation members 320 are fixedly disposed on the roll surface S1 of the main roll 3. The embossing member 340 and the opening member 320 are disposed to be not interfered with each other, i.e., the region where the embossing member 340 is disposed and the region where the opening member 320 is disposed do not overlap. The embossing member 340 and the perforation member 320 are fixed to the roll surface S1 of the main roll 3 and extend radially outward. The embossing elements 340 and the aperture elements 320 may be distributed at specific regular intervals on the roll surface S1, for example, may be distributed in an array on the roll surface S1. The surface 344 of the embossing member 340 facing away from the main roller 3 forms a main roller outer surface S2 outside the roller surface S1 of the main roller 3, i.e., a cylinder formed by the main roller outer surface S2 is coaxially parallel to and has a radius larger than that of a cylinder formed by the roller surface S1 of the main roller 3 and the cylinder formed by the roller surface S1 of the main roller 3. Thus, the embossing member 340 is adapted to cooperate with the second sub-roller 4 to emboss the fibrous layer and press the embossed face of the fibrous layer against the surface 344 of the embossing member 340 remote from the main roller 3, i.e. against the outer surface S2 of the main roller, to facilitate the engagement of the bonding means and the main roller during the bonding process.

In one embodiment, each embossing member 340 may be comprised of one or more embossing pins 346. When there are a plurality of embossing pins 346, the embossing pins 346 may be arranged in a specific rule or a specific pattern, for example, the number of the plurality of embossing pins 346 of each embossing member 340 may be 1, 3, 4, 8, and the number is not particularly limited in the present application. The plurality of embossing pins 346 may be arranged in a "cross shape", "star shape", "triangle shape", "curved shape", etc., and the present application is not particularly limited thereto.

The perforating element 320 is intended to perforate the fibre layer in cooperation with the first sub-roll 2. In one embodiment, each perforation member 320 may be comprised of one or more perforation pins 322. When there are a plurality of perforation needles 322, the perforation needles 322 may be arranged in a specific rule or a specific pattern. For example, the number of the plurality of perforation needles 322 may be 1, 5, 7, 13, and the number of the perforation needles 322 is not particularly limited in the present application. The plurality of perforation needles 322 may be arranged in a "snowflake type", "wintersweet type", etc., and this is not particularly limited in this application. In addition, the heights of the plurality of perforation pins 322 in one perforation member 320 may be the same or different. When the heights of the plurality of perforating needles 322 are different, for example, the height of the perforating needle 322 in the middle area is higher, and the height of the perforating needle 322 in the edge area is lower, so that when perforating is performed in the manufacturing process, the perforating in the central area on the formed bulge is larger, and the perforating in the edge area is smaller, so as to fit the arc shape of the bulge.

The height of the embossing member 340 needs to be greater than or equal to the height of the plurality of perforated members 320 so that the main roller outer surface S2 formed by the surface 344 of the embossing member 340 facing away from the main roller 3 is located radially outside the surface S3 formed by the apexes of the perforated members 320, thereby avoiding the provision of a patterned heating plate or a patterned heating member on the bonding device corresponding to the arrangement pattern of the embossing member 340, simplifying the complexity of the device, and saving the cost of the device. However, it is understood that the height of the embossing member 340 may be smaller than the height of the perforation member 320, so that the main roller outer surface S2 formed by the surface 344 of the embossing member 340 facing away from the main roller 3 is located radially inward of the surface S3 formed by the apex of the perforation member 320. At this time, a patterned heating plate or a patterned heating member corresponding to the arrangement pattern of the embossing member 340 needs to be provided on the bonding device to prevent the punching member from being pressed open. Those skilled in the art will appreciate that various embodiments of providing such a patterned heating plate or element on a bonding apparatus will not be described in detail herein.

The first sub-roll 2 is arranged to cooperate with the main roll 3. A plurality of first apertured pairs 220 are fixedly provided on the roll surface of the first sub-roll 2. The first plurality of aperturing members 220 are adapted to cooperate with the plurality of aperturing members 320 on the main roll 3 to form a first plurality of apertures in the first fibrous layer. It will be appreciated that the arrangement of the plurality of first aperture pairs 220 on the first sub-roll 2 corresponds to the arrangement of the plurality of aperture members 320. The fit gap between the first secondary roll 2 and the primary roll 3 can be adjusted depending on the material, thickness and/or temperature effect on the first fibre layer on both rolls. It is to be understood that the fit gap between the two rolls refers to the space left between the two rolls for the fiber layer when the rolls are rolled. In one embodiment, for the cooperation of the first secondary roll 2 and the primary roll 3, the fit gap refers to the distance between the roll surface S1 of the primary roll 3 and the surface S4 of the first aperture pair 220 facing the primary roll 3 closest to the roll surface S1 when rolling the first fiber layer. Typically, the fit clearance between the first secondary roll 2 and the primary roll 3 is slightly larger than the thickness of the first fibre layer.

In this embodiment, the first aperture pair 220 comprises an aperture boss 222 fixed to the roll surface of the first sub-roll 2. The surface of the perforating bosses 222 facing away from the first sub-roll 2 is provided with correspondingly arranged openings 224 cooperating with perforating needles 322. The height of the perforation needles 322 may be less than or equal to the depth of the corresponding openings 224, so that the perforation needles 322 can completely enter the corresponding openings 224 and not touch or just touch the bottom surfaces of the corresponding openings 224 when rolling. In addition, when the height of the perforation needles 322 is smaller than the depth of the corresponding openings 224, the perforation needles 322 are tapered, and the diameter of the thickest portion of the perforation needles 322 is smaller than the diameter of the corresponding openings 224, the size of the perforation can be controlled by the degree of the perforation needles 322 entering the openings 224. Such an arrangement may also ensure that the perforation pin 322 is not easily broken when adjusting the fit clearance.

The first fiber layer feeding mechanism 7 feeds the first fiber layer between the main roll 3 and the first sub-roll 2. In this embodiment, the first fiber layer feeding mechanism 7 is provided with a driving device. The driving device drives the first fiber layer feeding mechanism 7 to tension the first fiber layer and convey the first fiber layer to the position between the main roller 3 and the first auxiliary roller 2 through a cloth guide wheel 1.

Referring to fig. 1 in conjunction with fig. 3B, the second sub-roll 4 is disposed to cooperate with the main roll 2 and is disposed downstream of the first sub-roll 2. A plurality of embossing pairs 420 are fixedly provided on the roll surface of the second sub-roll 4. The plurality of embossing pairs 420 are adapted to cooperate with a corresponding plurality of embossing elements 340 to form a plurality of embossing surfaces on the first fibrous layer. It will be appreciated that the plurality of embossing pairs 420 on the second sub-roller 4 are arranged to correspond to the plurality of embossing members 340. The fit clearance between the second counter roll 2 and the main roll 3 can be adjusted depending on the material, thickness and/or temperature influence on the first fibre layer on both rolls.

In the present embodiment, the embossing member 340 includes at least one embossing pin, and the embossing counter member 420 includes a plurality of embossing grooves arranged correspondingly. The outer diameter of the embossing pin is smaller than the inner diameter of the embossing groove so that the embossing pin can extend into the embossing groove. The height of the embossing pin is smaller than or equal to the depth of the embossing groove, so that the embossing pin and the embossing groove are easy to joint, and the embossing pin is not easy to break when the fit clearance is adjusted.

With continued reference to fig. 3B, the surface 344 of the embossing pin 340 facing away from the main roller 2 is provided with a central recess 342. The projection of the central recess 342 on the surface 344 is located within the surface 344. Providing the central depression 342 in the center of the surface 344 reduces the area of the embossed surface, thereby reducing the hardened area and increasing the softness and breathability of the composite fiber layer without affecting the three-dimensional properties of the composite fiber layer. In the present embodiment, the shape of the central recess 342 is not particularly limited as long as the central recess 342 can reduce the area of the embossed surface without affecting the shape of the embossed pattern. It is to be understood that the surface 344 of the embossing pin 340 of the present application facing away from the main roller 2 may also have other relief patterns, as long as the relief patterns reduce the embossing area.

Further, it is also to be noted that, with the fitting of the second sub-roller 4 and the main roller 3 of the present embodiment, the fitting gap refers to a distance between the roller surface S1 of the main roller 3 and the surface S5 of the embossing counter 420 of the second sub-roller 4 closest to the roller surface S1, which faces the main roller 3. It will be understood that the fit clearance here may also refer to the distance between the bottom surface of the embossing grooves of the main roller 3 and the surface 344 of the embossing pins when the first fibre layer is rolled. Typically, the fit clearance between the second counter roll 4 and the main roll 3 is slightly larger than the thickness of the first fibre layer.

In a preferred embodiment, the fit gap between the main roll 3 and the first sub-roll 2 is smaller than the fit gap between the main roll 3 and the second sub-roll 4. The effect of trompil when can guaranteeing to punch like this, the effect of assurance impressed watermark again simultaneously.

With continued reference to fig. 1, a second fiber layer feeding mechanism 6 is provided for feeding the second fiber layer between the main roller 3 and the ultrasonic bonding mechanism 5 and the thermal bonding mechanism 9 in order to combine and bond the first fiber layer and the second fiber layer. In this embodiment, the second fiber layer feeding mechanism 6 is arranged similarly to the first fiber layer feeding mechanism 7, and will not be described again.

It should be noted that although the combination of the ultrasonic bonding mechanism 5 and the thermal bonding mechanism 9 is used in the present embodiment, it should be understood by those skilled in the art that the bonding mechanism may be at least one of a thermal bonding apparatus, a glue bonding apparatus or an ultrasonic bonding apparatus, and is not limited to only one manner of the present embodiment.

When the second fiber layer is fed to be combined with the first fiber layer, since the embossed surface of the first fiber layer is on the outermost surface of the main roll 3, i.e., the outer surface S2 of the main roll, the embossing member 340 cooperates with the ultrasonic bonding means 5 and the thermal bonding means 9 to press the first fiber layer against the second fiber layer at the embossed surface, so that the ultrasonic bonding means 5 and the thermal bonding means 9 thermally bond the first fiber layer and the second fiber layer at the embossed surface to obtain a composite fiber layer.

The composite fiber layer is continuously sent out by the main roller 3 and is conveyed to a forming cloth winding device 8 through a plurality of cloth guide wheels 1.

In another embodiment, the device further comprises a temperature adjusting device, wherein the temperature adjusting device is used for adjusting the temperature of the roller surface of each roller respectively, so that the roller surface temperature of the first auxiliary roller 2 is greater than or equal to the roller surface temperature of the second auxiliary roller 4, and therefore the punching and embossing can achieve good effects.

It should be noted that the hole-forming member 320 arranged on the roller surface and the step structure formed by the embossing member 340 and the roller surface S1 on the main roller 3 enable the main roller 3 to stably position and convey the fiber layer, so that the fiber layer has strong adhesiveness in the conveying process and is not easy to shift, thereby obtaining the composite fiber layer with accurate embossing pattern and high hole-forming quality, and improving the yield. Simultaneously, utilize first pair roller 2 and main roll 3 to punch first fibrous layer earlier, main roll 3 location and carry first fibrous layer to the vice roller 4 of second, recycle main roll 3 and the vice roller 4 of second and carry out the impressed watermark to first fibrous layer, then reuse the impressed watermark face to bond first fibrous layer and second fibrous layer, obtain the composite fiber layer of this application. With this kind of ingenious design that increases the running roller, owing to will punch technology and embossing process separately and handle for in punching technology and the embossing process like clearance, temperature etc. can all adjust to optimum state respectively and mutually noninterfere according to actual demand, thereby make the respective yields and the production speed of punching technology and embossing process all improve by a wide margin, not only improved the yields of making the composite fiber layer promptly generally, still improved its production speed, also prolonged equipment life. The inventor finds through research and experiment that the yield of the composite fiber layer manufactured by the device can reach 92%, and the rotating speed of the roller is at least improved to 62 m/min. Meanwhile, due to the good positioning performance of the fiber layer on the device provided by the application, the width range of the roller can be expanded to 800mm-1200mm, and the production efficiency of the composite fiber layer is further increased.

Referring now to fig. 2 in conjunction with fig. 3C, the embodiment shown in fig. 2 differs from that of fig. 1 in that fig. 2 also provides a third sub-roll 10 and a third fiber layer feeding mechanism 11. The third secondary roller 10 is arranged in cooperation with the main roller 2 and upstream of the first secondary roller 2. A plurality of second aperture pairs 1020 are provided on the roll surface of the third sub-roll 10. The second plurality of aperture elements 1020 are adapted to cooperate with the corresponding aperture elements 322 to form a second plurality of apertures in the third fibrous layer.

In this embodiment, the third fiber layer feeding mechanism 11 is used to feed the third fiber layer between the main roll 2 and the third sub-roll 10. In this embodiment, the third fiber layer feeding mechanism 11 is arranged similarly to the first fiber layer feeding mechanism 7, and will not be described again. It is noted that the ultrasonic bonding means 5 and the thermal bonding means 9 here bond the first and third fibre layers together with the second fibre layer.

Referring to fig. 4A to 4D, fig. 4A to 4D illustrate composite fiber layers having different patterns, which are made of fiber layers of different materials, manufactured under different manufacturing conditions using the composite fiber layer manufacturing apparatus provided in various exemplary embodiments of the present application.

Specifically, fig. 4A shows one pattern of the composite fiber layer. In this embodiment, each of the perforation members 320 includes 13 perforation needles 322, and the perforation needles 322 are arranged in a snowflake pattern, thereby forming 13 perforations 23 arranged in a snowflake pattern in fig. 4A. Each embossing element 340 includes three diamond-shaped embossing pins that share a common apex, thereby forming an embossing pattern consisting of the three diamond-shaped embossing surfaces 24 of fig. 4A. In this embodiment, the composite fiber layer is a double-layer composite fiber layer, the first fiber layer adopts a single-time hydrophilic material with a grammage of 23 g/sq m and a thickness of 0.35mm, and the second fiber layer adopts a multi-time hydrophilic material with a grammage of 18 g/sq m and a thickness of 0.25 mm. In addition, the effective width of the roll was 1200mm, the rotation speed of the roll was 60 m/min, the roll surface temperature of the first sub-roll 2 was 80 ℃, the roll surface temperature of the main roll 3 was 95 ℃, and the roll surface temperature of the second sub-roll 4 was 60 ℃. The bonding temperature of the thermal bonding means 9 was 110 ℃ and the bonding strength was 0.8N. The fit clearance between the main roll 3 and the first sub-roll 2 was 0.4mm, and the fit clearance between the second sub-roll 4 and the main roll 3 was 0.5 mm.

Fig. 4B shows yet another pattern of composite fiber layers. In this embodiment, each of the perforation members 320 includes 5 perforation needles 322, and the perforation needles 322 are arranged in a cross shape, thereby forming 5 perforations 23 arranged in a cross shape in fig. 4B. Each embossing member 340 includes an embossing pin formed of two concave curves that are axisymmetric, thereby forming the embossing pattern of fig. 4B formed of two concave curve type embossing surfaces 24 that are axisymmetric. In this embodiment, the composite fiber layer is a double-layer composite fiber layer, the first fiber layer is made of weak hydrophilic material and has a grammage of 21 g/sq m and a thickness of 0.3mm, and the second fiber layer is made of single-pass hydrophilic material and has a grammage of 16 g/sq m and a thickness of 0.2 mm. In addition, the effective width of the roll was 1200mm, the rotation speed of the roll was 55 m/min, the roll surface temperature of the first sub-roll 2 was 75 ℃, the roll surface temperature of the main roll 3 was 90 ℃, and the roll surface temperature of the second sub-roll 4 was 55 ℃. The bonding temperature of the thermal bonding means 9 was 100 ℃ and the bonding strength was 1.7N. The fit clearance of the main roll 3 and the first sub-roll 2 was 0.35mm, and the fit clearance of the second sub-roll 4 and the main roll 3 was 0.45 mm.

Fig. 4C shows yet another pattern of composite fiber layers. In this embodiment, each perforation member 320 comprises 7 perforation needles 322, said perforation needles 322 being arranged in a hexagonal pattern, thereby forming 7 perforations 23 in the hexagonal pattern of fig. 4C. Each embossing member 340 includes wedge-shaped embossing pins arranged in a cross-like pattern, thereby forming the embossing pattern of fig. 4C consisting of the wedge-shaped embossing surfaces 24 arranged in a cross-like pattern. In the embodiment, the composite fiber layer is a double-layer composite fiber layer, the first fiber layer is made of cotton fiber materials, the gram weight is 35 g/square meter, the thickness is 0.5mm, the second fiber layer is made of multi-time hydrophilic materials, the gram weight is 15.5 g/square meter, and the thickness is 0.2 mm. In addition, the effective width of the roll was 1200mm, the rotational speed of the roll was 65 m/min, the roll surface temperature of the first sub-roll 2 was 100 ℃, the roll surface temperature of the main roll 3 was 120 ℃, and the roll surface temperature of the second sub-roll 4 was 95 ℃. The ultrasonic bonding means 5 was used for bonding with a bonding strength of 1.0N. The fit clearance of the main roll 3 and the first sub-roll 2 was 0.56mm, and the fit clearance of the second sub-roll 4 and the main roll 3 was 0.58 mm.

Fig. 4D shows yet another pattern of composite fiber layers. In this embodiment, each of the perforation members 320 includes 7 perforation needles 322. Each embossing element 340 comprises wedge-shaped embossing pins arranged in a cross-like manner, so that a winter-like embossing pattern of the wedge-shaped embossing surfaces 24 arranged in a cross-like manner is formed in fig. 4D. In this embodiment, the composite fiber layer is a three-layer composite fiber layer, the first fiber layer is made of weak hydrophilic material with a grammage of 15 g/sq m and a thickness of 0.18mm, the second fiber layer is made of strong hydrophilic material with a single pass and a grammage of 13.5 g/sq m and a thickness of 0.16mm, and the third fiber layer is made of perforated PE film with a grammage of 17 g/sq m and a thickness of 0.2 mm. In addition, the effective width of the roll was 1200mm, the rotation speed of the roll was 62 m/min, the roll surface temperature of the first sub-roll 2 was 80 ℃, the roll surface temperature of the main roll 3 was 100 ℃, and the roll surface temperature of the second sub-roll 4 was 80 ℃. The ultrasonic bonding means 5 was used for bonding with a bonding strength of 1.8N. The fit clearance of the main roll 3 and the first sub-roll 2 was 0.41mm, and the fit clearance of the second sub-roll 4 and the main roll 3 was 0.51 mm.

Referring to fig. 5A-5C, fig. 5A is a schematic top view of the double-layer composite fiber layer formed by the manufacturing apparatus shown in fig. 1, fig. 5B is a schematic cross-sectional view of the double-layer composite fiber layer shown in fig. 5A taken along line F-F, and fig. 5C is a partial enlarged view of the schematic cross-sectional view shown in fig. 5B taken along line I.

Referring to fig. 5A, fig. 5A is a schematic top view illustrating a two-layer composite fiber layer according to an embodiment of the present disclosure. Each of the plurality of embossing members 340 is composed of three diamond-shaped embossing pins sharing a common apex. Correspondingly, the embossing surface 24 is formed in a corresponding pattern on the composite fibre layer, i.e. the pattern of the embossing surface is composed of three diamonds sharing a common apex. The embossed surface (or called adhesive surface) of each diamond extends along the periphery of the diamond. Since the center of the top surface of the embossing pin is provided with the central concave part, the center of each diamond in fig. 5A is formed with a bulge 22, and the bulge 22 is provided with a cavity, thereby improving the air permeability and softness of the composite fiber layer. A plurality of openings 23 are formed outside the rhombus formed by the embossed surface 24.

Referring to fig. 5B in conjunction with fig. 5C, in the cross-sectional view of fig. 5B, the fiber layer at the lowest layer is the second fiber layer 26. The upper fibrous layer is the first fibrous layer 21. With continued reference to FIG. 5C, the bulge 22 is located between two larger bulges. Both ends of the bulge 22 extend down to the embossing surface 24, where the first fiber layer 21 and the second fiber layer 26 are bonded to each other. A first opening 23 that opens downward is formed on the top surface of the bulge formed by the first fiber layer 21.

Referring to fig. 6A to 6C, fig. 6A is a schematic top view of the three-layer composite fiber layer formed by the manufacturing apparatus shown in fig. 2, fig. 6B is a schematic cross-sectional view of the three-layer composite fiber layer shown in fig. 6A taken along line H-H, and fig. 6C is a partial enlarged view of the schematic cross-sectional view shown in fig. 6B taken along line II.

Referring to fig. 6A, fig. 6A is a schematic top view of a three-layer composite fiber layer according to an embodiment of the present application. Each of the plurality of embossing members 340 is composed of three diamond-shaped embossing pins sharing a common apex. Correspondingly, the embossing surface 24 is formed in a corresponding pattern on the composite fibre layer, i.e. the pattern of the embossing surface is composed of three diamonds sharing a common apex. The embossed surface (or called adhesive surface) of each diamond extends along the periphery of the diamond. Since the center of the top surface of the embossing pin is provided with a central recess, the center of each diamond in fig. 6A has a bulge 28, resulting in good air permeability and softness of the composite fiber layer. A plurality of openings 25 are formed outside the rhombus formed by the embossed surface 24.

Referring to fig. 6B in conjunction with fig. 6C, in the cross-sectional view of fig. 6B, the fiber layer at the lowest layer is the second fiber layer 26. The middle fibre layer is the first fibre layer 21. The upper fibrous layer is the third fibrous layer 27. With continued reference to FIG. 6C, the bulge 28 is located between two bulges. Both ends of the bulge 28 extend down to the embossing surface 24, where the first fiber layer 21, the second fiber layer 26 and the third fiber layer 27 are bonded to each other. A second opening 25 that opens downward is formed on the top surface of the bulge formed by the third fiber layer 27. A first opening 23 that opens downward is provided on the top surface of the bulge formed by the first fiber layer 21 at a position corresponding to the second opening 25.

Referring to fig. 7, fig. 7 is a flowchart illustrating a method for manufacturing a composite fiber layer according to an embodiment of the present application. The method comprises the following steps:

step S100 of providing a manufacturing apparatus of the composite fiber layer according to any one of the above embodiments;

a step S120 in which the first fiber layer feeding mechanism feeds the first fiber layer between the main roller and the first sub roller, and the main roller and the first sub roller rotate in opposite rotational directions to each other and cooperate with each other to form the plurality of first openings in the first fiber layer;

a step S140 of positioning and conveying the first fiber layer by the main roller using the plurality of hole forming members, feeding the first fiber layer between the main roller and the second sub roller, the main roller and the second sub roller rotating in opposite rotational directions to each other and cooperating with each other to form a plurality of embossed surfaces on the first fiber layer;

step S160, the main roller positions and conveys the first fiber layer by using the plurality of hole-opening pieces, the first fiber layer is conveyed between the main roller and the bonding mechanism, the second fiber layer conveying mechanism conveys the second fiber layer between the main roller and the bonding mechanism, and the bonding mechanism bonds the first fiber layer and the second fiber layer to form a composite fiber layer;

and S180, positioning and conveying the composite fiber layer by the main roller by utilizing the plurality of hole-opening pieces, and sending out the composite fiber layer to roll up the formed cloth.

Fig. 8 is a flow chart of a method of manufacturing a composite fiber layer according to another embodiment of the present application. The method comprises the following steps:

step S200 of providing the apparatus for manufacturing a composite fiber layer according to the above embodiment;

step S220, the third fiber layer feeding mechanism feeds the third fiber layer between the main roller and a third sub roller, the main roller and the third sub roller rotating in opposite rotation directions to each other and cooperating with each other to form the plurality of second openings in the third fiber layer;

a step S240 of positioning and conveying the third fiber layer by the main roller using the plurality of opening members and feeding the third fiber layer between the main roller and the first sub-roller, and feeding the first fiber layer between the main roller and the first sub-roller by the first fiber layer feeding mechanism, the main roller and the first sub-roller rotating in opposite rotational directions to each other and cooperating with each other to form the plurality of first openings in the first fiber layer;

a step S260 of positioning and conveying the first fiber layer and the third fiber layer by the main roller using the plurality of opening members and feeding the first fiber layer and the third fiber layer between the main roller and the second sub roller, the main roller and the second sub roller rotating in opposite rotational directions to each other and cooperating with each other to form a plurality of embossed faces on the first fiber layer and the third fiber layer;

step S280, the main roller positions and conveys the first fiber layer and the third fiber layer by the plurality of hole-opening parts, and feeds the first fiber layer and the third fiber layer between the main roller and the bonding mechanism, the second fiber layer feeding mechanism feeds the second fiber layer between the main roller and the bonding mechanism, and the bonding mechanism bonds the first fiber layer and the third fiber layer with the second fiber layer to form a composite fiber layer;

and step S290, the main roller positions and conveys the composite fiber layer by utilizing the plurality of hole-opening pieces, and sends out the composite fiber layer to roll up the formed cloth.

The features of each element and step in the manufacturing method of the composite fiber layer provided in fig. 7 and 8 are explained in detail in the foregoing embodiments, and are not repeated herein.

The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.

The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.

Claims

1. An apparatus for manufacturing a composite fiber layer, comprising:

the main roller is provided with a plurality of embossing pieces and a plurality of perforating pieces on the roller surface;

the first auxiliary roll is arranged to be matched with the main roll, a plurality of first hole opening pieces are arranged on the roll surface of the first auxiliary roll, and the first hole opening pieces are used for being matched with the hole opening pieces to form a plurality of first holes in the first fiber layer;

a first fiber layer feeding mechanism for feeding the first fiber layer between the main roll and the first sub-roll;

the second auxiliary roller is matched with the main roller and arranged at the downstream of the first auxiliary roller, a plurality of embossing pairs are arranged on the roller surface of the second auxiliary roller, and the embossing pairs are used for being matched with the embossing pairs to form a plurality of embossing surfaces on the first fiber layer;

the bonding mechanism is used for bonding the first fiber layer and the second fiber layer; and

and the second fiber layer feeding mechanism is used for feeding the second fiber layer between the main roller and the bonding mechanism.

2. The apparatus of claim 1, wherein a fit gap between the main roller and the first secondary roller is less than a fit gap between the main roller and the second secondary roller.

3. The apparatus of claim 1, further comprising a temperature adjustment device for adjusting the temperature of the roll surface of each roll such that the roll surface temperature of the first sub-roll is greater than or equal to the temperature of the roll surface of the second sub-roll.

4. The apparatus of claim 1, wherein each of the plurality of aperturing members comprises at least one aperturing needle secured to a roll surface of the main roll; each of the plurality of first perforating paired pieces comprises a perforating boss fixed on the roller surface of the first auxiliary roller, at least one opening matched with the at least one perforating needle is arranged on the surface of the perforating boss, which faces away from the first auxiliary roller, and the height of the at least one perforating needle is less than or equal to the depth of the at least one opening matched with the perforating needle.

5. The apparatus of claim 1, wherein the embossing member includes a plurality of embossing pins, the embossing pair includes a corresponding plurality of embossing grooves, the embossing pins have an outer diameter that is less than an inner diameter of the embossing grooves such that the embossing pins can extend into the embossing grooves, and the embossing pins have a height that is less than or equal to a depth of the embossing grooves.

6. The device according to claim 5, characterized in that the surface of the embossing pin facing away from the main roller is provided with a central recess, the projection of which on the surface is located in the surface.

7. The apparatus of claim 1, wherein the bonding mechanism comprises at least one of a thermal bonding device, a glue bonding device, or an ultrasonic bonding device.

8. The apparatus of claim 1, further comprising:

a third secondary roller which is arranged to be matched with the main roller and is arranged at the upstream of the first secondary roller, wherein a plurality of second hole opening pieces are arranged on the roller surface of the third secondary roller and are used for being matched with the plurality of hole opening pieces to form a plurality of second holes on the third fiber layer; and

a third fiber layer feeding mechanism for feeding the third fiber layer between the main roller and the third sub-roller;

wherein the bonding mechanism is used for bonding the first fiber layer and the third fiber layer with the second fiber layer, and the second fiber layer feeding mechanism is used for feeding the second fiber layer between the main roller and the bonding mechanism so as to bond with the first fiber layer and the third fiber layer.

9. A method of manufacturing a composite fibre layer comprising:

providing a manufacturing apparatus of a composite fibre layer according to any one of claims 1-7;

10. A method of manufacturing a composite fibre layer comprising:

providing a manufacturing apparatus of the composite fiber layer according to claim 8;

11. A composite fibre layer formed in accordance with the apparatus of any one of claims 1 to 8.

12. An absorbent article made at least from the composite fiber layer of claim 11.