CN1286625C - 非织造织物穿孔装置及方法和由其制造的非织造织物 - Google Patents

非织造织物穿孔装置及方法和由其制造的非织造织物 Download PDF

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CN1286625C
CN1286625C CNB028132920A CN02813292A CN1286625C CN 1286625 C CN1286625 C CN 1286625C CN B028132920 A CNB028132920 A CN B028132920A CN 02813292 A CN02813292 A CN 02813292A CN 1286625 C CN1286625 C CN 1286625C
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CN1522190A (zh
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马蒂亚斯·穆特
拉尔夫·佐德曼
因德拉·罗伊
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Abstract

本发明涉及一种带有一穿孔辊(4)和一配对辊(5)的非织造织物穿孔装置(1)。穿孔辊(4)和配对辊(5)形成一间隙(9)，待穿孔的非织造织物(6)通过该间隙并被穿孔。非织造织物穿孔装置(1)有一非织造织物输入装置(8)和一非织造织物输出装置(12)。非织造织物输入装置(8)是这样布置的，以使待穿孔的非织造织物(6)在导入间隙(9)之前首先导到配对辊(5)上。非织造织物输出装置(12)是这样布置的，以使已穿了孔的非织造织物(10)在离开间隙(9)之后保持处于穿孔辊(4)上；为了获得稳定的穿孔，待穿孔的非织造织物(6)在配对辊(5)上有一个至少为45°的包缠角，以及，已穿了孔的非织造织物(10)在穿孔辊(4)上有一个至少为45°的包缠角。另外，提出了一种穿孔方法和一种相应的非织造织物。

Description

非织造织物穿孔装置及方法和由其制造的非织造织物
技术领域
本发明涉及一种带有一穿孔辊和一配对辊的非织造织物穿孔装置以及一种织物穿孔的方法，这样制造的非织造织物及包括这样的非织造织物的产品。
背景技术
对于吸收液体或微粒，非织造织物穿孔具有优点。例如，从US5,858,504可以知道一种制造方法、制造装置及如上所述穿了孔的非织造织物。这个制造方法规定借助于一针辊和一与针相对的带孔辊将一非织造织物穿孔。此外此装置还有二个S-辊装置。该S-辊装置快慢不同，以致于经由两个S-辊装置通过的非织造织物由于速度差而在穿孔前受到拉伸。穿孔后，穿了孔的非织造织物仍留在配对辊上，并将被导向第二S-辊装置。配对辊也同针辊一样，二个都不加热，这样，非织造织物在所使用的聚合物的熔点以下被穿孔，从而不能获得稳定的穿孔。
发明内容
本发明的任务是，提供一种非织造织物穿孔装置、一种用于对非织造织物穿孔的方法、一种非织造织物及包括这样的非织造织物的产品，它们为使用和进一步加工获得稳定的穿孔。
这个任务将通过本发明的非织造织物穿孔装置、用于非织造织物穿孔的方法、非织造织物来实现。
按本发明的非织造织物穿孔装置有一穿孔辊和一配对辊。穿孔辊和配对辊形成一间隙，待穿孔的非织造织物通过这个间隙并被穿孔。此外，非织造织物穿孔装置有一非织造织物输入装置和一非织造织物输出装置。非织造织物输入装置是这样布置的，以使待穿孔的非织造织物在导入间隙之前先导到配对辊上。非织造织物输出装置是这样布置的，以使已穿孔的非织造织物在离开间隙之后优选保持一定时间处于穿孔辊上。
穿孔辊优选是一针辊。针具有特别是同心的直径。此外，针也可有其它直径几何形状，例如星形、直角形或半角形。根据一改进规定，待穿孔的非织造织物在配对辊上有一至少为45度的包缠角，优选大于90度的包缠角。另外，优先的是穿了孔的非织造织物在穿孔辊上有一至少为45度的包缠角，优选大于90度的包缠角。
一个进一步改进规定，非织造织物穿孔装置有一为待穿孔的非织造织物的加热装置。
另一个进一步改进规定，在非织造织物输入装置与配对辊之间可确定地调整作用于待穿孔的非织造织物上的拉应力。一个附加的构型规定，非织造织物穿孔装置在穿孔辊与非织造织物输出装置之间有一可确定地调整的拉应力作用于穿了孔的非织造织物上。优选把在非织造织物输入装置与配对辊之间的拉应力调整为比在穿孔辊与非织造织物输出装置之间的拉应力大。
一种特别不依赖于此的构想规定，提供一种用于非织造织物穿孔的方法，其中，非织造织物由一非织造织物输入装置导向在穿孔辊和配对辊之间的间隙，非织造织物在间隙中被穿孔，非织造织物在穿孔后导向一非织造织物输出装置，且非织造织物在穿孔前以一大于45度的包缠角缠绕配对辊。非织造织物在非织造织物输入装置和配对辊之间，在其包缠配对辊之前，预拉伸1.5％到10％。预拉伸特别在机器方向(MD)上发生，但也可在横向方向(CD)上发生。
导到配对辊上的预拉伸的非织造织物的优点是，由于在配对辊与非织造织物之间的摩擦力，预拉伸的非织造织物被固定。预拉伸因此特别有利，因为位移了的纤维通过随后的固定保留在其位置上。这一固定将至少保持到穿孔辊同配对辊把非织造织物穿孔后。举例来说，作为非织造织物输入装置使用一S-辊装置，通过此S-辊装置将在这个非织造织物输入装置与配对辊之间对非织造织物作用一拉应力。通过在非织造织物与配对辊之间的摩擦力，非织造织物保留它的位置上。这种固定类型特别允许，非织造织物输入装置与配对辊之间的作用于非织造织物上的拉力可不依赖于在穿孔辊和配对辊后面设置的其它装置如转向辊等地调整。
非织造织物在穿孔后优选以至少45度的包缠角缠绕穿孔辊。此外，先前贴靠在配对辊上的非织造织物，在穿孔时或就在其前后，转向穿孔辊。通过穿孔辊的一定旋转路程，非织造织物在穿孔辊上的持续固定导致穿孔在非织造织物本身内进一步稳定。非织造织物优选以一在90度到270度之间的包缠角缠绕穿孔辊。
根据本发明的另一个构想，用非织造织物穿孔装置或如上描述的方法生产非织造织物。非织造织物具有接近圆形的穿孔。特别是穿孔具有接近于1的MD比CD的轴长比，优选在1和1.18之间。这种非织造织物优选用于一种产品，其中非织造织物在产品表面上具有稳定的漏斗形开口。这些开口通过在穿孔方法中或在穿孔装置上的穿孔形成。
这种穿孔非织造织物特别可用于在卫生领域中使用的产品中。这些可是尿布、绷带、(大小便)失禁用品等等。在医疗用品如护盖卫品、防护服，其中部分以及在家务用品方面，例如在抹布中，这种非织造织物也都作为产品的组成部份得到应用。另外到处，特别是在那些一方面一定大小的孔是优先的，另一方面像吸收液体或吸收微小颗粒的性能是重要的地方，都可使用。例如可把非织造织物表面配备成亲水的，比如借助于添加物或涂层。所使用的非织造织物也可是带静电的。此外，非织造织物可是单层或多层的、同薄膜或其它载体材料一起构成层压制品。这种材料特别可用于局部应是透液体或透蒸汽的地方。
对于至少二层材料的有利的待穿孔材料的例子可从下表得出：
  第二层的材料   第一层的材料
  纺粘型非织造织物PP   纺粘型非织造织物PE
  梳理的PP   纺粘型非织造织物PE
  纺粘型非织造织物PP   纺粘型非织造织物BICO，例如PP/PE
  纺粘型非织造织物PP   梳理的BICO，例如PP/PE，优选包括PET(例如在10％到40％之间)
  薄膜PP   薄膜PE
  非织造织物PP   薄膜PE
  纺粘型非织造织物BICO PP/PE   纺粘型非织造织物PE
  纺粘型非织造织物BICO PP/PE   薄膜PE
  非织造织物PP   高膨化性的非织造织物BICO PP/PE
  纺粘型非织造织物HDPE   梳理的BICO，例如PP/PE，优选包括PET(例如在10％到40％之间)
  非织造织物PP   梳理的PE
  非织造织物PP   低熔点的PP非织造织物，例如SoftspunTM
  纺粘型非织造织物BICO PP/PE   梳理的BICO PP/PE，
测试了单位面积重量如下：
 第二层的单位面积重量[gsm]  第一层的单位面积重量[gsm]
 从大约10到大约50  从大约10到大约50
优选的是，第一层的单位面积重量大于第二层的单位面积重量。
试验结果如下：
  样品   单位面积重量[g/m2]   延伸率[％]   轴长比MD/CD   孔面积[mm2]   开孔面[％]
  A   43   2.8   1.01   1.45   22.3
  B   43   1.7   1.13   1.46   22.4
  C   30   2.2   1.04   1.38   21.1
  D   25   5.6   1.11   1.31   20.7
  E   30   3.5   1.16   1.24   18.9
其中：
延伸率：紧靠间隙前的制品宽度与制品原始宽度的比值，单位为％
轴长比：孔的纵轴与横轴的平均比值，假设为椭圆，MD＝机器方向以及
        CD＝横向
孔面积：孔的平均面积，单位为mm2(用MediaCybemetics公司的图形
        处理程序Image-Pro Plus 4.5版计算)
开孔面：孔面积与非织造织物总面积的平均比值，单位为％
在所有的试验中，针在穿了孔的配对辊中的穿入深度为2.7mm。所使用的样品是预制非织造织物(Vorlagenvliess)，其作为纺粘型非织造织物制造成。
样品A：双层的按Docan-过程制造的材料，其中上层有由PP制成的20gsm的非织造织物，而下层有由PP/PE-Bico制成的23gsm的非织造织物；
样品B：同样品A；
样品C：由PP制成的单层30gsm的非织造织物，按Docan-过程制造；
样品D：同C，但为25gsm；
样品E：由PP制成的单层30gsm的非织造织物，按S-Tex-方法制造；
如同特别是孔的尺寸比MD/CD表明的那样，也能使特别是穿孔的圆形开口稳定。孔直径在MD上在1与1.8mm之间，而在CD上在0.8与1.7mm之间。非织造织物优选有一预应力，它使延伸率处在2％与3％之间。
非织造织物通过非织造织物穿孔装置的速度对孔的尺寸有其他影响。非织造织物以从5m/s到130m/s之间的速度通过。从45m/s到120m/s之间的速度，特别是从60m/s到95m/s之间的速度证明对制造一稳定的穿孔是有利的。在0.5mm以下范围的穿孔直径下，可调节更高的操作速度。这里可调整到200m/s的速度，优选大于150m/s的速度。孔直径这时例如在0.5与0.1mm之间的范围。配对辊的温度优选在45℃与95℃之间，特别是在55℃与75℃之间。
按另一构想，非织造织物穿孔装置有一用于待穿孔的非织造织物的输入装置，它布置成使非织造织物在穿孔进行之前，经过一超过120°的、优选超过150°的包缠角沿配对辊进行。由此特别可做到，在加热了配对辊的情况下，非织造织物被(预)加热地输送给穿孔辊。此外，由于包缠，在处于与配对辊接触中的材料中的应力将减小。由此可达到特别稳定的穿孔。
按另一种构造，配对辊有一涂层，优选橡胶层。涂层厚度特别是在1.5mm与15mm之间，特别是至少4mm厚。穿孔辊的突起可嵌入涂层。嵌入深度优选从约2.5mm到约6mm。
一个双层的待穿孔的塑料压层制品(Laminat)将按一构型在一种集成的制造方法中生产。例如在非织造织物制造中，有一个带有一个或多个梁(Balken)的纺粘型非织造织物机供使用。借助于一个梁制造比如低熔点的聚合物混合物，而借助第二个梁制造BICO PP/PE非织造织物。此外也可以在一预制好的材料上涂覆上一个第二层，并染后接着穿孔。此外也有可能，第一层和第二层都在线制造，并在一与此相分开的加工过程中穿孔。如同在非织造织物的例子中所表明的，还有使用薄膜与非织造织物组合的可能性。例如可把薄膜挤压到比如梳理的非织造织物上，并接着送到穿孔单元上。
按另一种构型，第一层的纤维至少部分地与第二层非织造织物的纤维相混和，特别是以互相搭接的形式。在例如二个互相分开制造的非织造织物层时，在它们之间可有一材料分界，而两个至少部分地互相混和的非织造织物层却有一材料过渡。除材料过渡之外，其中一层与另一层一样都只有一热塑性材料。这种结构将特别借助于一种在线方法制造。穿孔结构优选有一相变，或按另一构型至少部分地在穿孔区有一比如完全的纤维搀和。第一层和第二层优选用同样方式制造。两层例如都是在相同的机器上生产的挤压非织造织物。也有可能，各有不同性能的不同材料形成一个穿孔结构。在非织造织物至少大部分是PP时，而另一种非织造织物则大部分由HDPE或DAPP构成。由此存在非织造织物的不同制造方法的组合可能性，特别是使用高膨化性短纤维非织造织物与纺粘型非织造织物组合或者熔吹非织造织物与纺粘型非织造织物组合，以及其它组合。
塑料压层制品及非织造织物在产品中应用的例子是卫生用品、清洁用品和家务用品，特别是抹布、医学用品、产品中的表面应用、过滤材料、防护服、建筑工业用纺织品、用即弃产品。
附图说明
其它有利的构型和改进可从后面的附图中得出，然而它们不应在其构型方面限制本发明。图中示出的特征和改进也可与上述本发明其它的此外未进一步说明的构型相组合。附图中：
图1一个带有一开卷装置和一卷绕装置的非织造织物穿孔装置；
图2图1中的局部放大视图，从中可看出待穿孔的非织造织物及已穿了孔的非织造织物从非织造织物穿孔装置的配对辊向穿孔辊的位置变换；
图3a、b  一待穿孔的单层材料；以及
图4a、b  一待穿孔的双层材料。
具体实施方式
图1示出一个带一开卷装置2和一卷绕装置3的非织造织物穿孔装置1。也可规定用其它加工站代替开卷装置2和卷绕装置3。例如可把一个直接的纺粘型非织造织物、短纤维非织造织物和/或熔吹(Meltblown)非织造织物制品放在非织造织物穿孔装置1之前。也可规定用裁剪机、边织单元、喷射单元，如抹布之类产品的生产装置等等来代替卷绕装置3。优选一预加强的非织造织物或者一由单层或多层非织造织物或带有其它材料比如薄膜的非织造织物构成的塑料压层制品，从开卷装置2输送给穿孔辊4。穿孔辊4有穿孔装置。在这种情况中穿孔辊4做成针辊。在穿孔辊4对面布置有配对辊5。配对辊5优选有同穿孔辊4一样的旋转速度。由开卷装置2输入的待穿孔的非织造织物6将通过进料辊7置于配对辊5上。进料辊7特别是这样布置的，使得在非织造织物输入装置8与配对辊5之间有一定拉应力作用在待穿孔的非织造织物6上。优选非织造织物输入装置8有一拉力测量辊(Zugmesswalze)。待穿孔的非织造织物6从非织造织物输入装置8过来这样置于配对辊5上，以使其至少部分地包缠后者。优选配对辊5被直接加热。配对辊5的温度特别要低于待穿孔的非织造织物6中使用的聚合物的或所使用的塑料压层制品的软化温度或熔点。当待穿孔的非织造织物6被带过时，通过配对辊5优选传递这样的温度控制。另外存在非织造织物通过未详细示出的加热装置在穿孔前被加热的可能性。这时力图使非织造织物具有低于所使用的聚合物的熔点的温度。待穿孔的非织造织物6从配对辊5导入由穿孔辊4与配对辊5形成的间隙9。在间隙9中待穿孔的非织造织物6被穿孔并按这个非织造织物穿孔装置1导到穿孔辊4那边。被穿了孔的非织造织物10被穿孔辊4的针11从穿孔辊导向非织造织物输出装置12。在非织造织物输出装置12后，如所示那样布置有另外的输出辊13。优选非织造织物输出装置12有一拉力测量辊。穿了孔的非织造织物10从输出辊13到达卷绕装置3。优选对穿了孔的非织造织物10作用有一拉应力，它小于作用在待穿孔的非织造织物6上的拉应力。穿了孔的非织造织物10在穿孔辊4上沿一定的包缠角被带过。以这种方法使非织造织物中的穿孔稳定。通过由非织造织物输出装置12相应地在处于非织造织物输出装置12与穿孔辊4之间的穿了孔的非织造织物10施加一拉力，穿孔将优选附加地稳定。此外，穿孔辊4还同样可调节温度。对穿了孔的非织造织物10以及相应的塑料压层制品的热输入使以这种方式位移的非织造织物纤维稳定。
按照一种改进，配对辊5的温度比穿孔辊4至少高400℃。另一种构型规定，配对辊5是可调节温度的，而穿孔辊4则不是。相反，后者还可冷却到比如约18℃和更低。
图2示出图1的一个局部截面，在其中更详细地示出穿孔辊4、配对辊5以及待穿孔的非织造织物6，它将变成穿了孔的非织造织物10。穿孔辊4的一部分嵌入到配对辊5中。导入到在配对辊5与穿孔辊4之间形成的间隙中的非织造织物通过这种嵌入被穿孔。穿孔优选通过非织造织物纤维的位移而进行。由此纤维结构至少在非织造织物表面上保留下来。特别是纤维仅仅被位移，而不熔化或软化。纤维性能例如优选沿纤维导出液体的性能，由此而保留下来。通过非织造织物从配对辊5向穿孔辊4的迂回引导，穿孔这样保持在稳定的状态中。在这种情况中，针11嵌入非织造织物。针11优选也嵌入配对辊5的覆层14。覆层14自己也可有孔，它们与针11相对布置。
图3a和3b示出一单层非织造织物。图3a表示待穿孔的非织造织物6，而图3b表示已穿了孔的非织造织物10。从图3b可看出，穿孔15可以是锥形的。穿孔种类使锥形构造18稳定化，以使其作为突起从非织造织物底层升起。
图4a和4b示出一双层材料的穿孔，其中第一层16是非织造织物，第二层17可以是非织造织物或其它材料。例如第二层可以是薄膜。第一层16和第二层17也可以是不同的或相同的非织造织物种类。第一层16具有穿孔15，它以锥形构造18延伸到第二层17。构造18优选做成不伸出第二层17的表面。优选第二层17近乎完全地、不带第一层16材料地形成表面。按一种改进结构，双层材料从一个漏斗形构造18到下一个漏斗形构造18，至少在朝向漏斗形构造18升起的那一面上，可有一轻微的波纹。与之相对的面则相反，优选近乎是平面的。

Claims (11)

1.一种非织造织物穿孔装置(1)，带有一穿孔辊(4)和一配对辊(5)，其中穿孔辊(4)和配对辊(5)形成一间隙(9)，一待穿孔的非织造织物(6)通过该间隙并被穿孔，并且非织造织物穿孔装置(1)有一非织造织物输入装置(8)和一非织造织物输出装置(12)，其特征为：非织造织物输入装置(8)是这样布置的，以使待穿孔的非织造织物(6)在导入到间隙(9)之前先导到配对辊(5)上；而非织造织物输出装置(12)是这样布置的，以使已穿了孔的非织造织物(10)在离开间隙(9)之后保持处于穿孔辊(4)上；为了获得稳定的穿孔，待穿孔的非织造织物(6)在配对辊(5)上有一个至少为45°的包缠角，以及，已穿了孔的非织造织物(10)在穿孔辊(4)上有一个至少为45°的包缠角。
2.按权利要求1的非织造织物穿孔装置(1)，其特征为：所述穿孔辊(4)是针辊。
3.按权利要求1或2的非织造织物穿孔装置(1)，其特征为：待穿孔的非织造织物(6)在配对辊(5)上有一个大于90°的包缠角。
4.按权利要求1的非织造织物穿孔装置(1)，其特征为：已穿了孔的非织造织物(10)在穿孔辊(4)上有一个大于90°的包缠角。
5.按权利要求1的非织造织物穿孔装置(1)，其特征为：非织造织物穿孔装置(1)有一用于待穿孔的非织造织物(6)的加热装置。
6.按权利要求1的非织造织物穿孔装置(1)，其特征为：在非织造织物输入装置(8)与配对辊(5)之间能确定地调整一个作用在待穿孔的非织造织物(6)上的拉应力。
7.按权利要求1的非织造织物穿孔装置(1)，其特征为：在穿孔辊(4)与非织造织物输出装置(12)之间能确定地调整一个作用在已穿了孔的非织造织物(10)上的拉应力。
8.用于非织造织物(6)穿孔的方法，其中：
-非织造织物(6)由一非织造织物输入装置(8)导入到一穿孔辊(4)与一配对辊(5)之间的间隙(9)中，
-非织造织物在间隙(9)中被穿孔，
-非织造织物在穿孔后输送给一非织造织物输出装置(12)，
-非织造织物在穿孔前以一大于45°的包缠角缠绕配对辊(5)，以及
-非织造织物(6)在非织造织物输入装置(8)和配对辊(5)之间，在缠绕配对辊(5)之前，预拉伸1.5％-10％。
其特征为：
非织造织物在穿孔后以一至少为45°的包缠角缠绕穿孔辊(4)。
9.按权利要求8的方法，其特征为：非织造织物以一在90°与270°之间的包缠角缠绕穿孔辊(4)。
10.通过按权利要求1的非织造织物穿孔装置(1)和通过按权利要求8的方法制造的非织造织物(10)，其特征为：非织造织物(10)具有从1.7％到5.6％的延伸率以及穿孔的轴长比MD/CD在1与1.18之间。
11.按权利要求10的方法，其特征为：非织造织物(10)具有从2％到3％的延伸率。
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