CN1988864B - 用于生产具有颗粒材料图案的夹芯结构的方法 - Google Patents

用于生产具有颗粒材料图案的夹芯结构的方法 Download PDF

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Publication number
CN1988864B
CN1988864B CN2005800249047A CN200580024904A CN1988864B CN 1988864 B CN1988864 B CN 1988864B CN 2005800249047 A CN2005800249047 A CN 2005800249047A CN 200580024904 A CN200580024904 A CN 200580024904A CN 1988864 B CN1988864 B CN 1988864B
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pattern
carrier material
granular materials
transfer device
carrier
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CN1988864A (zh
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霍斯特·布莱辛
汉斯-阿道夫·杰凯尔斯
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Procter and Gamble Co
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Procter and Gamble Co
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Priority claimed from EP04017789A external-priority patent/EP1621165B1/en
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Abstract

本发明涉及一种用于形成在复合材料中的充分定义的颗粒材料图案的方法，所述复合材料包含材料纤维网和颗粒状吸收材料。本发明还涉及用于确定用于这样一种工艺的设备设计和加工参数的方法。在特定应用中，本发明提供一种用于制备例如可用于一次性吸收制品的液体吸收结构的方法。

Description

用于生产具有颗粒材料图案的夹芯结构的方法
技术领域
本发明是一种用于形成在复合材料中的充分定义的颗粒材料图案的方法，所述复合材料包含材料纤维网和颗粒状吸收材料。本发明还涉及用于确定用于这样一种工艺的设备设计和加工参数的方法。在特定应用中，本发明提供一种用于制备例如可用于一次性吸收制品的液体吸收结构的方法。
背景技术
包括呈特定图案的颗粒材料的复合结构已为本领域所熟知，参见例如EP-A-1447066(Busam等人；P&G)，其公开了一种用于吸收制品的吸收芯，所述吸收芯具有在润湿时被固定住的颗粒吸收材料。所述吸收芯包括一个吸收材料例如吸收性聚合物材料的基质层。
US-B-4381783(Elias)公开了一种具有包括吸收性水胶体材料的穴窝的芯部的吸收制品。提供这些穴窝来限制吸收性聚合物材料的移动，尤其是在制品完全或部分地装有尿液时。穴窝形成吸收层的一部分并典型地由纤维素材料来提供。因此，为获得吸收性聚合物材料良好的固定性，依照这个发明的讲授，需要相当多的纤维素材料。此外，此类穴窝构造会阻碍液体自由分布到芯部的更多的吸收区域，例如吸收性聚合物材料的区域。
因此，生产具有不均匀分布的吸收材料例如颗粒吸收性聚合物材料(通常称作吸收胶凝材料或称作超吸收剂)的吸收制品的工艺也是已知的。在WO 03/101622A2(Tombült等人；P&G)中公开了一种用于产生不连续颗粒分布的脉冲工艺，并且可依照US 5213817(Pelley；McNeill PPC)生产类似的结构。
目的在于将颗粒吸收材料的图案沉积到一个纤维网上的工艺被描述于美国专利4800102(Takada；Nordson)中，其采用了转动掩模，或描述于WO92/019198A(Perneborn/
Figure G05824904720070125D000011
)中，其显示了直线移动的掩模。FR-A-2583377(Piron；Colgate Palmolive)公开了一种其中从漏斗供入吸收剂粉末的计量转筒，用于在传送带上的载体上形成不连续图案。转筒以步进运动进行操作。
US-5494622(Heath等人；K-C)是针对在以高速移动的纤维网上按所期望的图案产生颗粒穴窝。图案室被供应高吸收性材料的颗粒，可透气的纤维网通过其在具有开口图案的表面上进行传输，通过开口图案抽取真空，以使颗粒能够按表面上的开口图案被沉积在纤维网上。承载颗粒的纤维网被一层液体可透过的材料所覆盖并且施加到可渗透的纤维网上的张力进行变化以改变纤维网的孔隙度。颗粒按所期望的穴窝图案保持在纤维网上，同时去除在穴窝之间的多余颗粒。如此形成的穴窝形成“孤岛”，即它们完全被粘合区所包围。
尽管此类文件描述了将颗粒材料沉积到表面上或移动基质上的各种方法，仍然存在着对于按充分定义的图案和以高的生产速度生产成图案的颗粒夹芯的方法的需要。
此外，尽管每一个所述方法的某些特定最佳条件可从这些公开的内容中读出或推导出来，但目前没有普遍可行的方案来教给人们如何用最好的工艺装置获得最合适的设计。具体地讲，用于改变边界条件，象改变图案或敷设基重，例如对于完整的生产范围所必需的。
应用数学建模模拟来分析工艺和/或工艺参数已为本领域所熟知，例如由US-B-6529860(Strumolo等人；FORD)可知。其中，采用了各种与计算机有关的工具来帮助汽车的设计和测试，具体地讲关于调查汽车覆盖件上的土壤沉积。
然而，迄今为止尚未提供用于模拟形成颗粒图案的颗粒敷设系统的解决办法。具体地讲，尚未应用于一次性吸收制品的制造。
发明内容
因此，在一个方面，本发明为一种产生包括以充分定义的图案夹在材料纤维网之间的颗粒材料的夹芯结构的工艺。该工艺包括以下步骤：
-在转移装置上的图案形成部件上产生这样的预定图案，
-将由此所形成的图案沉积在一个载体材料纤维网上，
-用一种覆盖材料纤维网覆盖这个载体材料上的图案，
-和粘合载体和覆盖材料纤维网以形成夹芯结构，从而使所述图案固定。
因此，其提供了：颗粒材料；包括用于将颗粒材料安放在一个接纳区域中和将它转移到一个卸料区域的第一图案形成部件的转移装置；作为载体的基本平坦的材料纤维网和/或形成夹芯外层的覆盖材料；用于具有与转移装置的第一图案形成部件的图案相对应的支撑图案的载体的基本环形的载体支撑部件；用于将载体材料暂时附连到载体支撑部件的表面上的载体材料保持部件；和用于结合夹芯结构的夹芯固定部件。
载体和覆盖材料可为一体的，用于形成两个外夹芯层，或可为不同的材料，形成外夹芯层；
所述工艺还包括执行以下步骤：将颗粒材料转移到转移装置的接纳区域，在此处第一图案形成部件确定一个颗粒簇图案；将颗粒材料的图案移动到转移装置的卸料区域；以与载体支撑速度相对应的载体速度将载体材料纤维网导引到载体支撑部件上；用载体材料保持部件使载体材料纤维网变形，使得在未受支撑区域形成了一个低凹，从而形成与颗粒簇图案相对应的图案；从转移装置朝向载体排出颗粒材料；将所排出的颗粒材料沉积在变形的纤维网载体材料上；将覆盖材料施用到载体材料和成图案的颗粒材料上，从而形成夹芯结构，提供用于至少在一部分粘合区域将外夹芯层彼此粘合的固定部件。
进而在另一方面，本发明是一种方法，该方法用以确定用于有选择地将颗粒材料放置在移动表面上的工艺的设备设计和工艺参数，通过：
1)提供一组物理方程以形成一个物理模型，所述物理方程组通过相互影响边界条件相连接，任选地包括通过子模型连通边界条件所连接的子模型，
2)选择一组固定边界条件(包括整个设备装置、整个工艺要求)和一组(初始)运行条件(固定模型输入)，
3)提供一组预定模型目标，
4)选择一组可变边界条件，其可在一次模拟过程中改变(可变模型输入)，
5)通过利用固定和可变模型输入在物理方程上执行计算操作，
6)将计算结果转换成模型输出值，其对于分析人员来说是直接可读的或优选地借助于计算装置是可读的；
7)将模型输出与预定的模型目标相比较并确定其之间的偏差，
8)修改可变边界条件组，优选地通过利用使模型输出与预定模型目标之间的偏差最小的计算公式；
9)重复步骤4)至8)直到预设的退出判据得到满足为止。
优选地，这些步骤采用一个计算机装置来执行。迭代可通过确定一个预设的迭代数目或通过确定一个预设的模型输出和预定模型目标之间的退出偏差标准来终止。
在又一个方面，本发明是一种用于确定有选择地将颗粒材料放置到一个移动表面上的工艺的设备设计和工艺参数的系统，所述系统包括一个存储器装置和一个与所述存储器装置连通设置的处理器，所述处理器被构型为：
a)接受虚拟模拟程序和所有的边界条件；
b)模拟目标；
c)和初始模拟参数
以计算一组预定的输出参数并将所述输出参数传递到一个输出装置。
附图说明
图1为其中上层被部分切掉的一次性尿布的顶部平面视图。
图2显示图1一次性尿布的横截面视图。
图3A显示吸收芯夹芯结构的顶视图。
图3B为图3A的夹芯图案的横截面视图。
图4A形成夹芯结构的示意性工艺图。
图4B为如图4a所示工艺的一部分设备的示意性放大截面图。
具体实施方式
本文使用的下列术语具有下列含义：
“吸收制品”是指吸收和容纳液体的装置，更具体地讲是指与穿着者的身体紧贴或邻近放置用于吸收和容纳由身体排放的多种渗出物的装置。吸收制品包括但不限于尿布、成人失禁贴身短内裤、训练裤、尿布固定器和衬里、卫生巾等等。
“尿布”是指通常由婴儿和失禁者围绕下体穿着的吸收制品。
本文所用术语“一次性的”用来描述一般不旨在洗涤或换句话讲不旨在恢复或重新使用的制品(即旨在单次使用后就丢弃它们，并且优选回收、堆肥处理，或换句话讲以环境相容的方式进行处理)。
“包括”(其动名词形式和动词单数形式)是一个非结论性术语，其指定其后所述例如一个组分的存在，但不排除本领域已知的或本文公开的其它特性、元件、步骤或组分。
术语“材料纤维网”是指在一个方向，即纵向尺寸、或长度、或相对于材料纤维网的笛卡尔坐标的x方向上基本无端的材料。包含在这个术语中的是由基本无端材料裁切或换句话讲分离的基本无限制的片序列，材料纤维网将具有明显小于纵向尺寸(即，在x方向上)的厚度尺寸(即z向)。通常，尽管不一定，材料纤维网的宽度(y向)将明显大于厚度，但小于长度。通常，尽管不一定，此类材料的厚度和宽度基本上沿着纤维网的长度保持不变。此类材料纤维网可为(并非用来进行任何限制)纤维素纤维材料、薄纸、织造或非织造材料等等。典型地，尽管不一定，材料纤维网以卷筒形式、或在卷轴上、或在箱中以折叠状态进行供应。然后个体递送被拼接到一起以形成基本无端的结构。材料纤维网可由几种材料纤维网例如多层非织造材料、涂敷薄纸、非织造材料/薄膜层压材料组成。材料纤维网可包括其它材料，例如添加的粘合材料、颗粒、亲水剂等等。
本文所用术语“超吸收剂”、“超吸收材料”或“SAM”、“吸收性胶凝材料”或“AGM”、“吸收性聚合物材料”是可互换的，并且是指局部交联的聚合材料，其可吸收水并同时可溶胀形成凝胶。
本发明为一种用于成图案的夹芯结构的高效和精确生产方法，其中颗粒材料以充分定义的量和成图案的分布夹在材料纤维网之间。
本发明特别适用于连续生产工艺，其中颗粒材料以散装形式进行供应并且载体纤维网为基本无端的材料纤维网，其在后续工序过程中可被切分成单个的纤维网片，并且其可形成加工制品的一部分。这样一种结构尤其适于一次性吸收制品，例如但不限于一次性婴儿尿布、训练裤、成人失禁制品、妇女卫生制品等等。根据预期的用途和/或使用者，就所需的吸收性而论，此类制品的要求变化很大。在此类实施方案中，载体材料纤维网可为流体可渗透的纤维网，例如非织造材料。
所述颗粒材料可为任何颗粒材料。当夹芯结构为用于吸收制品的液体吸收结构时，颗粒材料优选地为所谓的超吸收材料。
在本发明的范围之内，术语夹芯结构是指一种载体材料和一种覆盖材料、以及其中间设置有颗粒材料的基本分层的排列。载体和覆盖材料典型地彼此相附连。颗粒可或不可彼此相附连和/或附连到载体/覆盖材料上。如果载体和/或覆盖材料具有光滑的表面，则颗粒典型地将继续停留在这个表面上。取决于颗粒的大小和表面粗糙度或载体/覆盖材料的孔隙度，有些颗粒材料可穿透进这些材料中。
典型地，尽管不一定，载体和/或覆盖材料将为材料纤维网，其包括这样一种材料纤维网的切片。载体和覆盖材料可为同一材料种类，或可为不同的材料种类。载体和覆盖材料也可为一体的，例如当载体材料的横向侧部被折叠到中央部分上之时。
颗粒材料的图案被认为包括多个颗粒簇，每个颗粒簇包括多个颗粒(参见图3)。在颗粒簇已经产生之后，颗粒簇可存在于夹芯结构中。颗粒簇也可在生产工艺的过程中出现，例如在预计量颗粒材料和预先形成所述图案时。夹芯结构中的颗粒簇也可包括来自不同预成型簇或预成型簇的仅一部分的颗粒。优选地，在制造工艺期间所产生的颗粒簇被转移到夹芯结构而不改变形状或形态。
这样一种颗粒簇可包括少至约10个颗粒，但也可多达几百个乃至几千个颗粒。颗粒可基本上按“单层”结构或厚度基本不变的多层结构进行排列，或可具有变化的厚度。这种厚度可按覆盖颗粒层的数目来表示，或可通过局部或平均基重来表示，平均基重指的是给定单位面积的颗粒重量。技术人员将容易认识到，甚至“局部”基重将也需要某种数量的平均。然而，当给定区域中的基重在这个区域范围内有意设计为不为常数时，例如在一堆或一簇颗粒材料的情况下朝向区域的中心会增大，基重分布可通过沿着过这个堆的横截面视图而行的光滑曲线近似得到。可供选择地，一个区域的基重可设计成在整个区域上不变，使得该区域的平均基重、任选地连同其某些变化一起可被确定。相邻区域的基重可相同，但并非要求如此。
多个簇形成一个主图案，其中各簇以任何几何方式被间隔开。这样一种图案可包括少至两簇，然而典型地将包括超过十簇。通常，它将包括不到1000簇。任何多个簇可形成规则的或不规则的主图案的子图案。簇可为离散的或不相连的区域，使得这些区域中的每一个基本上均被基本上不含颗粒的区域所包围。
典型地，颗粒基本上被排列成彼此直接接触，即，每个颗粒将与至少一个其它颗粒接触。然而，它也可处于另一种情况，即它们彼此不接触。然而，在簇内相邻颗粒之间的距离通常将小于在主图案或子图案内相邻颗粒簇的距离。(图3A，B)
尽管以基本连续的排列形成图案，图案将具有某种重复，这种重复将使同一图案能够在随后的制品中复现。因此，术语“宏图案”是指这样一种重复图案，即其每一个可形成这样一种制品的元件。
除了簇中颗粒材料的几何排列之外，对于具体应用场合，数量通常是关键的。自此，具体地讲，当每一个簇中颗粒材料数量均不同时，材料的精确计量是最重要的。
通常，夹芯结构将需要满足由预定用途所确定的一组要求。尽管不被看作限制，典型的此类要求组可为：
-颗粒材料的数量和分布，包括轮廓清晰的图案定义在内；
-夹芯结构的尺寸和形状；
-关于允许适当的制造和包装，以及关于预期用途的夹芯结构的机械性质：强度、弯曲性、柔软性以不负面影响使用期间的舒适性；
-粘合夹芯结构的各元件；
-在干态以及湿态两种状态下夹芯结构内的颗粒材料的固定性；
-在基本无端的夹芯结构的长度范围内或在基本无端的结构所切成的片之间任何要求的可变性。
用于制造此类夹芯结构的工艺应当不仅满足产品设计和质量标准，而且还应当是一种高效的方法。典型地，这样一种工艺将能够以高生产速度连续生产，这就要求材料纤维网速度超过每秒0.5米乃至超过每秒10米。所述工艺也应当非常灵活以允许快速改变产品设计例如由一种尺寸变到另一种尺寸。所述工艺以及设备将是耐用的以使停产修理时间达到最少。
本发明提供了一种满足所有以上要求的工艺。这通过提供一种制造方法(参见图4)来实现，所述制造方法包括以下步骤：
-通过利用一个图案形成部件或转移装置产生呈预定图案的预计量数量的颗粒材料，
-将颗粒材料按颗粒簇图案沉积在载体材料上，
-用覆盖材料覆盖该载体材料上的图案，
-和粘合载体和覆盖材料纤维网以形成夹芯结构，从而使所述图案固定。
此外，重要的是所有的工序以及对应的设备设计参数彼此正好适合。
不希望限制本发明，下面的示例性说明集中在可适宜地用于一次性吸收制品例如婴儿尿布、训练裤、成人失禁产品或妇女卫生垫的吸收芯的吸收结构的制造上。
图1和2描述了一种示例性的吸收结构。图1是作为本发明吸收制品一个优选实施方案的尿布20的平面视图。所述尿布以其平展未收缩状态(即，无弹性引起的收缩)示出。结构的一部分被切掉以更清楚地显示尿布20的下层结构。尿布20接触穿着者的部分朝向观察者。图1中尿布20的底座22包括尿布20的主体。底座22包括一个外覆盖件，外覆盖件包括液体可透过的顶片24和/或液体不可透过的底片26。底座可包括包封在顶片24和底片26之间的一部分吸收芯28。底座也可包括包封在顶片24和底片26之间的大部分或全部吸收芯28。底座优选地还包括侧片30、弹性化腿箍32和弹性腰部组件34，腿箍32和弹性腰部组件每个典型地均包括弹性构件33。尿布20的一个端部36被构型为尿布20的第一腰区。相对的端部38被构型为尿布20的第二腰区。尿布20的中间部分37被构型为裆区，裆区在第一和第二腰区36和38之间纵向延伸。腰区36和38可包括弹性构件使得它们围绕着穿着者的腰部聚拢以提供改进的贴合性和密封性(弹性腰部组件34)。裆区37是当尿布20被穿用时，通常位于穿着者大腿之间的尿布20的部分。用尿布20的纵向轴线100和它的横向轴线110来描述尿布。尿布20的周边被尿布20的外边缘限定，其中纵向边缘44通常平行于尿布20的纵向轴线100延伸，并且在两个纵向边缘44之间的端边46通常平行于尿布20的横向轴线110延伸。底座还包括扣紧系统，它可包括至少一个扣紧构件40和至少一个着陆区42。
对于一体的吸收制品，底座22包括添加了其它组件形成复合尿布结构的尿布主要结构。尽管顶片24、底片26和吸收芯28可以多种熟知的构型进行组装，优选的尿布构型通常描述于1996年9月10日授予Roe等人的名称为“Absorbent Article With Multiple Zone Structural Elastic-Like FilmWeb Extensible Waist Feature”的美国专利5,554,145、1996年10月29日授予Buell等人的名称为“Disposable Pull-On Pant”的美国专利5,569,234和1999年12月21日授予Robles等人的名称为“Absorbent Article WithMulti-Directional Extensible Side Panels”的美国专利6,004,306中。
图1和2中的顶片24可被完全或部分弹性化或者可被缩短以提供在顶片24和吸收芯28之间的空隙空间。包括弹性化的或缩短的顶片的示例性结构更详细地描述于1991年8月6日授予Allen等人的名称为“Disposable Absorbent Article Having Elastically Extensible Topsheet”的美国专利5,037,416和1993年12月14日授予Freeland等人的名称为“Trisection Topsheets for Disposable Absorbent Articles and DisposableAbsorbent Articles Having Such Trisection Topsheets”的美国专利5,269,775中。
图1中的吸收芯28通常被设置在顶片24和底片26中间。除了如本文下面所述的吸收性夹芯结构之外，吸收芯28可包括任何吸收材料，其通常是可压缩的、适形的、对穿着者的皮肤无刺激性的并且能够吸收和容纳诸如尿液和其它某些身体流出物之类的液体。吸收芯28可包括多种液体吸收材料，这些材料通常用于一次性尿布和其它吸收制品，例如一般称为透气毡的粉碎木浆。其它适用的吸收材料实施例包括绉纱纤维素填料；熔喷聚合物，包括共成型；化学硬化、改性或交联的纤维素纤维；薄纸，包括薄纸包装材料和薄纸层压材料；吸收泡沫；吸收海绵；超吸收聚合物；吸收胶凝材料；或其它任何已知的吸收材料或材料的组合。吸收芯28可包括液体存储区域60和其它液体处理元件50，例如采集层52和/或分配层54。吸收芯28还可包括少量(典型地少于10％)的非液体吸收材料，例如粘合剂、蜡、油等等。
用作吸收组合件的示例性的吸收结构描述于美国专利4,610,678(Weisman等人)、美国专利4,834,735(Alemany等人)、美国专利4,888,231(Angstadt)、美国专利5,260,345(DesMarais等人)、美国专利5,387,207(Dyer等人)、美国专利5,397,316(LaVon等人)和美国专利5,625,222(DesMarais等人)中。
底片26可与顶片24相接合。底片26防止被吸收芯28所吸收并包含在制品20内部的渗出物污染可能接触尿布20的其它外部制品，例如床单和内衣。在优选的实施方案中，底片26基本不能透过液体(例如尿液)并且包括一张非织造层压材料和一张薄塑料薄膜，例如厚度为约0.012毫米(0.5密耳)至约0.051毫米(2.0密耳)的热塑性薄膜。合适的底片膜包括由印第安纳州Terre Haute的Tredegar Industries，Inc.制造并以商品名X15306、X10962和X10964出售的那些产品。其它适合的底片材料可包括允许水蒸汽从尿布20选出同时还可防止排泄物透过底片26的透气性材料。示例性透气材料可包括诸如织造纤维网、非织造纤维网之类的材料、诸如膜包衣的非织造纤维网的复合材料以及诸如日本的Mitsui Toatsu Co.制造的命名为ESPOIR NO和德克萨斯州Bay City的EXXON ChemicalCo.制造的命名为EXXAIRE的微孔薄膜。包括共混聚合物的适用透气复合材料以名称HYTREL blend P18-3097购自俄亥俄州Cincinnati的Clopay Corporation。此类透气复合材料更详细地描述于1995年6月22日以E.I.DuPont的名义公布的PCT专利申请WO 95/16746中。包括非织造纤维网和开孔成型膜的其它可透气底片描述于1996年11月5日授予Dobrin等人的美国专利5,571,096中。
尿布20还可包括这些本领域已知的其它特征，包括前耳片和后耳片、腰部覆盖片、松紧带等以提供较好的贴合性、存储性和美观特性。此类附加特征已为本领域所熟知并被例如描述于美国专利3,860,003和美国专利5,151,092中。
为了保持尿布20处在环绕穿着者的位置，优选地至少第一腰区36的一部分由扣紧构件42连接到第二腰区38的至少一部分上，优选形成腿部开口和制品腰部。当扣紧时，扣紧系统承受制品腰部周围的拉伸载荷。设计扣紧系统使得制品的使用者能够手握扣紧系统的一个构件，例如扣紧构件42，然后至少在两个位置将第一腰区36连接到第二腰区38。这通过操纵扣紧装置元件之间的粘结强度来实现。依照本发明的尿布20可装设一个可重新闭合的扣紧系统或可供选择地可以裤型尿布形式提供。
依照本发明的吸收结构的实施方案包括一个层压结构，通常也称作“夹芯”结构。这是指具有两个基本平直的外层的设计，外层为材料纤维网或此类材料纤维网的切片，如可以是诸如由亲水聚合材料制成的薄纸、织造或非织造材料等等之类的夹芯材料纤维网。一种优选的材料是由纺粘层、熔喷层和另一纺粘层构成的所谓SMS材料。高度优选的是永久性亲水非织造材料，并且具体地讲为具有耐久亲水涂层的非织造材料。可供选择的优选材料包括SMMS-结构体。
顶层56和底层58可由两个或多个单独的材料片来提供或者它们可供选择地可由一体的材料片来提供。这样一个一体材料片可以例如C型折叠方式包裹在储存层60周围。
优选的非织造材料由合成纤维提供，例如PE、PET，而最优选PP。因为用于非织造制品的聚合物本身是疏水的，它们优选涂有亲水涂层。生产具有耐久亲水涂层的非织造材料的优选方法是通过将亲水单体和自由基聚合引发剂施用到非织造材料上和进行通过导致单体化学结合到非织造材料的表面上的紫外光所激发的聚合反应，如共同未决的欧洲专利申请EP-A-1403419中所述。
存储层60位于两层材料纤维网之间并包括一种颗粒材料，具体地讲上面提到的超吸收材料。典型地，这些颗粒材料呈不规则的形状或球形颗粒，其在与液体例如尿液接触时会溶胀。尽管这种材料可呈各种形状或形式，例如颗粒状、球状、片状、纤维状，它通常将由形状不规则的颗粒组成，所述颗粒的平均粒度为约10μm至1000μm，优选地粒度为5μm的按重量计少于5％，以及优选地粒度超过1200μm的按重量计少于5％。
已发现，用颗粒吸收性聚合物材料作为本发明制作的吸收芯是有益的。不受理论的束缚，据信此类材料(甚至在溶胀状态，即已经吸收了液体时)基本上无法阻碍液体流过整个材料，尤其是在用吸收性聚合物材料的盐水流动传导率所表示的渗透性大于10、20、30或40SFC单位时，此处1SFC单位为1×10-7(cm3×s)/g。盐水流动传导率为本领域所熟知并将根据EP752 892 B(Goldman等人；P&G)中所公开的试验进行测量。
当采用此类夹芯结构时，存在着很多部分矛盾的要求，这些结构应满足这些要求以得到合格性能。
因此，颗粒材料优选地被固定住。这是指在生产期间以及使用期间将这些颗粒保持在所述结构中。在现代制品中，在制品的不同部件中的吸收性要求可非常不同，使得例如在装载点附近比在远处要求更多的吸附以及吸收材料。一旦产品设计标准已经确定了吸收分布特征图，这应当在制品的整个使用周期以及具体地讲在使用期间均被产生和保持。
此外，颗粒材料应当能够无限制地溶胀。甚至例如上文所述的现代吸收材料显示吸收性能在某种程度上取决于在其上所施加的压力。这种压力可为有规律的使用压力，例如当作为使用者的婴儿坐在制品上之时。然而，这样一种压力可在夹芯结构中产生，例如当外材料纤维网层56和58以不允许膨胀的方式彼此紧密结合时，因此降低了所述结构的吸收性能。
一种进一步的重要要求与整个结构纵向(长度或x方向)和横向(宽度或y方向)两个方向液体分布有关，但也和沿着结构的厚度(或z方向))的液体分布有关。
考虑典型的婴儿尿布设计，吸收结构的总体设计要求通常可遵从EP-1447066的说明并可为如下：
应将超吸收颗粒材料夹在非织造材料纤维网之间。
颗粒材料具有约400μm的典型中值粒度，并可为可商购获得的材料。非材料纤维网可为基重为每平方米20克或更小的常规亲水SMS聚丙烯纤维网。颗粒材料将以分离的“簇”图案进行沉积。所述簇(参见图3A、B)将具有约5毫米的xy方向上的均匀尺寸和约10毫米的距离。在各自的簇之间，一个基本无颗粒的粘合区将具有至少3毫米的圆形尺寸。相邻簇不应被连续的粘合线或区域分隔开。
在各个簇中的颗粒材料的数量可变化，从直径15毫米的每簇最多约0.25克(其与一簇内每平方米1500克的平均基重相对应)到最少为这个数值的1％。
颗粒材料典型地由一个颗粒存储系统供应给所述工艺，并且通常将以散装形式进行供应。散装是指以下事实，即许多颗粒可通过与单个颗粒有关的性质和参数例如成分、大小、形状、颗粒密度等等进行描述，但也通过与很多此类颗粒有关的性质和参数例如体积密度、粒度分布或堆积流动性进行描述。
如上文背景章节中所述的通用颗粒沉积系统的速度依赖性通常很强，并且当以高速运行时，产生或是无法接受的损失或是相对于放置和施用重量的可变性。整个工艺包括两个子工艺段，第一段是预计量和图案形成，以及第二段是将颗粒材料的图案夹在载体和覆盖材料之间。
图4可见到示意性的工艺表示，其显示颗粒材料供应410，分别用于载体材料320和覆盖材料330的供应420和430，载体支撑部件470和颗粒转移装置440的任选元件。其也显示了在载体材料320和覆盖材料330之间具有颗粒材料310的所得夹芯结构300。
颗粒材料通常由一个颗粒存储系统供应给所述工艺，并且通常将以散料形式进行供应。散料是指以下事实，即许多颗粒可通过与单个颗粒有关的性质和参数例如成分、大小、形状、颗粒密度等等进行描述，但也通过与多数此类颗粒有关的性质和参数例如体积密度、粒度分布，或流动性质进行描述。
颗粒材料被沉积在材料纤维网的移动表面上。因此，所述工艺可示例性地被描述成将来自散料存储系统的颗粒按规则图案放置到材料纤维网上。
此类工艺不仅要求颗粒材料的精确放置，而且应当适合于高的乃至非常高的“加工”速度，其在现有范围内通常与移动表面的速度相对应。
如上文背景章节中所述的很多现有的颗粒沉积系统的速度依赖性通常很强，并且当以这样的高速运行时，产生或是无法接受的损失或是相对于放置和施用重量的可变性。
引入本文以供参考的共同未决的欧洲专利申请(律师签号CM2877FQ)提供了一种前述困难的解决方案，通过提供一种用于将吸收性胶凝材料颗粒间接施用到用于吸收制品尤其是尿布的载体层上的方法，其中粒状颗粒通过一个转移装置由散料存储系统进行承接。参见图4，转移装置440具有在表面上的凹槽452，其中其数目、尺寸和位置决定转移装置440所承接的超吸收颗粒310的数量和图案。转移装置440可从与散料存储系统410相邻的载料位置442移动到载体层320与转移装置相邻的卸料位置448。转移装置还具有一个用于在转移装置440移动到卸料位置448期间将超吸收颗粒保持在其凹槽内的部件444和一个用于将颗粒在卸料交汇位置448处排出到载体层上的部件446。优选地，这些部件分别是真空和鼓风。
为了保持颗粒材料的图案，在载体材料320上形成了低凹328。基本所有由转移装置440的一个凹槽452所排出的颗粒材料均被转移到在载体材料上所形成的相应的低凹328中，因此形成夹芯图案的簇。
尽管将要求特殊的工艺和设备布置来执行从凹槽到载体的基本完整转移，低凹的形成极大地提高了这种转移的质量。低凹328通过将载体材料320放置在载体材料支撑部件470上来形成，载体材料支撑部件470具有一个基本无端的表面，并可用一个转动的转筒或环形的传送带系统来形成。载体材料支撑部件具有形成载体材料的特定支撑图案的表面结构(参见图6A)。除了被支撑结构的支撑图案所支撑的区域外，载体材料基本上不受支撑，使得在拉力作用下，它可变形或凸起，形成一个穴窝(图4B)。这样一种拉力可为真空吸力，例如可以支撑转筒或以布置在与载体材料的接受侧相对、并且颗粒材料将被沉积到其上的表面结构一侧上的真空箱来施加。
所述工艺还包括以下步骤：将其上具有颗粒材料的载体材料与覆盖材料330相结合，和用一个固定部件495例如喷雾粘合剂粘合载体和覆盖材料。
载体材料纤维网的变形以及表面图案的具体方面可见于共同提交的专利申请(律师签号CM2988FQ)，并且其全部公开内容均清楚地引入本文以供参考。
对于本发明而言，重要的是在凹槽中所形成的颗粒图案被精确地转移到载体材料纤维网上，分别进入在该载体材料纤维网上所形成的穴窝中。生产速度越高，这种转移逐渐变得更加难以控制，即使颗粒转移装置和载体材料纤维网以“匹配速度”(即，各表面相对于固定机架具有基本相同的速度)移动。
这是由于离心力、重力、阻力(例如，将颗粒在象空气一样的流体中移动)的矛盾影响的缘故，具体地讲在颗粒簇移动之时。此外，当颗粒碰到载体材料纤维网的表面或者已经沉积在那里的其它颗粒时，这些颗粒可能被偏转并再次弹回或弹回其它颗粒(“回弹”效应)。
总的趋势将是，生产速度越高，颗粒散开的就越多，即当颗粒簇被排出转移装置470的凹槽452时，簇中的颗粒将具有不保持在一起的趋势。这可导致轮廓不清晰的图案定义，并且颗粒可着陆在应当无颗粒的区域，或者甚至着陆在相邻的低凹中。
尽管在载体材料纤维网中穴窝的形成提供了这个区域的改进，焦点应进一步放在设备设计以及具体地讲放在气流的控制上。
在颗粒材料被沉积在低凹或穴窝中之后，这些低凹或穴窝可被颗粒部分或完全充满，或者这些穴窝可能过满，例如形成一个“堆”。在任何一种情况下，重要的是载体材料表面的至少一部分基本上无颗粒材料以提供一个粘合区域，粘合区域基本上不含颗粒材料。典型地，该区域将与载体支撑图案相对应，但可仅为其一部分或通常将大于载体支撑图案，包括围绕载体支撑区域的区域在内。
夹芯结构的形成通过用一种覆盖材料覆盖穴窝中的成图案的颗粒材料和将两种材料彼此互相固定(例如通过将粘合剂材料至少施用到载体材料的粘合区上或施用到覆盖材料的对应区域上)来完成。
尽管以上说明将使技术人员能够正确地设计设备以及执行这样一种工艺，下面将描述本发明的另一方面，即如何很快地得出设备设计和工艺参数的方法，具体地讲对夹芯结构要求上的变化的反应。
因此，本发明使用计算机虚拟模拟工具。此类工具具有日益增加的用户友好性，与此同时计算机也已经变得更适于处理复杂的数学模拟模型。然而，选择和组合正确工具以及将这些工具应用于适当的问题迄今尚未被用于解决在生产速度增加时变图案夹芯结构的形成问题。
通常，存在着太多可利用的数学/物理模拟途径，例如不限制：
-基本有限元分析，允许三维(3D)几何模拟；
-在加入时间作为变量时，可能动态地模拟运动。
-将质量加入到几何3D模拟中，允许实体和表面的模拟。
-将力加入到模拟中将导致动力学模拟；
-加入能量(势能)将允许力和能量转换的相互作用，具体地讲也允许流体动力学。
此外，可将特定的具体元素加入到上面模拟的每一个和任何一个中。此类元素可为温度、压力、化学物质的活动性等。
所有这些模拟的整个方法是建立一个有代表性的真实工艺的物理和数学模型，即建立与物理结构或工艺有关的数学方程。对于所有这些方程而言，应提供合适的边界条件以使解方程组能够给出对于该组条件的解答。
现在将通过利用一次性吸收制品例如上面所述的尿布的制造工艺进一步解释这些一般讲解。
模型可建立在用于特定模拟的常规建模工具上。因此概括地说，可将虚拟模拟描述成是一种用于确定旨在有选择地将颗粒材料放置到一个移动表面上的工艺设备设计和工艺参数的方法，通过：
1)提供构成物理模型的一组物理方程，所述物理方程组通过相互影响的边界条件相连，任选地包括通过子模型连接边界条件连接的子模型；
2)选择一组固定边界条件，包括整个设备装置，整个工艺要求和一组(初始)运行条件(固定模型输入)；
3)提供一组预定的模型目标
4)选择一组可变边界条件，所述边界条件可在一次模拟期间改变(可变模型输入)；
5)通过使用固定和可变模型输入在物理方程上执行计算操作；
6)将计算结果转换成模型输出量，通过直接地或优选地借助于计算装置，所述模型输出量对于分析人员来说是可读的；
7)优选地通过使用计算机将模型输出量与预定模型目标相比较并确定其之间的偏差；
8)修改可变边界条件组，优选地通过使用用于使模型输出量与预定模型目标之间的偏差最小的计算方程；
9)重复步骤4)至8)直到预设退出判据满足为止；退出判据优选地为某个迭代数目，更优选地为模型输出量和预订模型目标之间的预设退出偏差。
优选地，模拟将通过使用一个例如可包括一个连接到用户界面上的处理单元的计算机系统执行，计算机系统可包括显示器终端、键盘、指点装置例如鼠标等等。处理单元可包括中央处理单元、存储器和存储的指令，其执行一种帮助确定依照本发明的工艺和设计参数的方法。存储的指令可被存储在存储器中的处理单元内，或存储在任何非易失性存储器例如磁或光介质、EPROM、EEPROM等等中。可供选择地，指令可由移动介质例如移动磁盘(有时称作软盘)、光介质等等进行载入。在一个优选的实施方案中，系统包括一个通用计算机程序以实施本文所述的功能。任选地，计算机装置也可包括一个打印机或一个用于接入局域服务器、内联网和因特网的网络连接器。
具体地讲，现有方法利用了虚拟模拟和计算工具。
可通过使用统计、动力学或运动学模型设计各种设备元件。用于此类计算的典型工具为MSC.visualNASTRAN 4DTM或MSC.DynamicDesignerTM，其均可购自美国加利福尼亚州Santa Ana的MSC.Software Corporation。
当计算在整体流动中的颗粒的行为并且具体地讲计算颗粒之间的相互影响时，用于此类计算的典型工具可见于2维或3维中的“Particle FlowCode”(PFC2D/PFC3D)，例如通过德国Gelsenkirchen的Itasca Consultants购自HCItasca。
一个重要的模拟方面涉及流体流图案，其可通过计算流体动力学(CFD)求解器例如如购自美国新罕布什尔州Lebanon的Fluent IncorporatedFLUENT、FloWizard、FIDAP、POLYFLOW来解决。
一种更重要的模拟工具涉及在例如由流过材料的空气所引起的外力的撞击下材料例如材料纤维网的变形。一种适用的工具已经见于ANSYSMechanicalTM，如购自美国宾夕法尼亚州Canonsburg的ANSYS Inc.。
在选择了合适的工具之后，将要设置第一组边界条件。这与“固定”条件有关，“固定”条件在模拟期间将基本保持不变，并与材料定义有关，在本文中是颗粒材料或材料纤维网。在目前情况下，其它通用边界条件是在“环境”条件下运行，具体地讲所述工艺将在或围绕着正常空气条件下运行，然而，空气条件可稳定在例如20℃，50％相对湿度。“环境”压力条件可包括设备的某些部分可经受某种压力变化(例如真空)以引发空气流动。
类似地，与主要设备元件有关的固定边界条件，对于生产一次性尿布的夹芯结构的情况，在夹芯结构被覆盖和附连之前，颗粒材料将以散料被递送到一个通过预计量和转移转筒计量的漏斗系统并被转移到作为载体的材料纤维网上。
尽管这些边界条件对于给定模拟将不改变，这些边界条件可以并且典型地将进行改变以评估例如所述系统的稳健性。
在另一步骤中，将设定目标参数。在目前情况下，这些目标参数可为吸收性夹芯结构的设计参数，例如图案的几何形状、数量、基重和材料的分布等等。对于模拟而言，一个重要的目标参数是预设工艺速度。这些目标典型地为了整个工艺而被界定，尽管某些方面可仅与一个或多个子工艺步骤有关。
模型计算可作为一个完整迭代来运行或者可有子模型组的迭代。在使用子模型的情况下，它们可自动地相连，使得一个建模程序将子模型边界条件传递到一个相连的其它子模型。可供选择地，子模型可逐步执行，即每个模拟步骤可独立于另一个步骤进行，并且来自一个步骤的边界条件将被输入到下一次模拟中。
对于每个子系统而言，将定义一组输入参数以及一组结果参数。
在第一模拟步骤中，考虑了将颗粒材料转移到图案形成装置上。
起始点是将夹芯中的目标设计图案“转换”为簇尺寸的分布、基重以及“转换”到凹槽的初始设计。
这样一个模拟步骤的结果将是要设计的转移转筒凹槽的初始设计(深度、形状…)。确定凹槽的总尺寸为直径2-25毫米，并且深度将从约0.5毫米变化至约10毫米。与具有比单层颗粒所要求的颗粒材料少的簇相对应的凹槽将以较小的直径制成以能够精确填充。
在考虑颗粒与颗粒间的力和压力时，可调查凹槽的填充以获得凹槽的详细设计，包括侧壁的斜度、边缘曲率、颗粒递送装置(例如漏斗)与凹槽的相对布置、使用或如果使用的话，刮削部件的距离(例如刮粉刀)。同样，将估算通过凹槽的可透气底部的真空施用值。
后续模拟步骤是将颗粒充满凹槽从颗粒接受区域移动到颗粒排出区域。当考虑稳定旋转的圆柱体转移转筒的优选实施方案时，其需要平衡离心力和抑制力(例如由转移转筒内的真空所引起的空气流动力)。
一种关键模拟步骤与将颗粒从转移或印刷辊转移到载体材料纤维网上有关。这具有很多相互影响的因素，即将颗粒排出凹槽之外；将颗粒朝向载体移动；与气流的相互作用以及由颗粒簇自身引发的气流干扰；以及颗粒和颗粒簇轨迹线的计算。理想的是，颗粒在簇中的相对放置不会改变，即簇应当从转移转筒中“按原样”转移到载体材料。在颗粒轨迹线的区域上的空气流模拟需要进一步考虑辅助空气流。
这种模拟的结果将是转移装置相对于载体纤维网支撑部件的精确布置、排出颗粒的精确点和对应的状态；以及辅助空气流(例如如来自粘合剂喷剂的干扰)的确认。
为了设计载体材料的穴窝，必须模拟两个重要的方面：第一，低凹的图案将反映对于最终夹芯结构所需的图案。第二，低凹的形成需要考虑载体材料的变形性能。纤维网的非各向同性应力应变行为可导致图案的倾斜排列。
可将另外的模拟工具应用于其它工艺方面，并且然后可被连接到可能与它们相干涉的相应模拟步骤上。用于这样一个工序的一个实施例是在颗粒沉积之前和/或之后将喷雾粘合剂施用到纤维网载体材料上，这将干扰颗粒周围的空气流动。进一步的实施例可以是设计所有元件的结构设计方面。
在因此确定了迭代程序之后，模拟步骤将开始，并将进行迭代直到达到预设目标为止，或者任何其它中止判据得到满足为止(例如自动迭代数目)。
对于以每秒8米的生产速度生产如本文上面所述的吸收性夹芯结构已经进行了模拟。模拟结果允许设计改进的工艺，具体地讲为：
通过改进凹槽的形状改进凹槽的填充；
调整用于将颗粒保持在凹槽中的真空；
计算用于排出颗粒的合适的“鼓风”；
在从转移装置排出之后，估算对颗粒轨迹冲击的完整空气流图案；
通过施加真空吸力形成低凹使载体材料变形；
确定各个颗粒簇的颗粒在载体材料上的着床。
这些模拟已经被转化成使用模拟结果所设计的大规模生产单元，并且生产试验证实了使用模拟结果来以至少每秒4.2m米的高生产速度制备具有充分定义的颗粒图案的夹芯结构的可能性。
发明详述中所有引用文献的相关部分均引入本文以供参考；任何文献的引用并不可理解为是对其作为本发明的现有技术的认可。
尽管已用具体实施方案来说明和描述了本发明，但对于本领域的技术人员显而易见的是，在不背离本发明的精神和保护范围的情况下可作出许多其它的变化和修改。
本文为其确定了数值的每个参数均为技术参数，其在本发明的范围内不能按字面进行理解。因此，具有就其功能等同于本文所述参数的参数的所有实施方案旨在被本发明的范围所涵盖，例如“10毫米”的长度应被理解成“约10毫米”的含义。

Claims (1)

1.一种用于连续生产夹芯结构(300)中的颗粒材料图案的方法，所述方法包括以下步骤：
提供
-颗粒材料(310)；
-转移装置(440)，所述转移装置用于在接纳区域(442)中接纳所述颗粒材料(300)并将其转移到卸料区域(448)，
-所述转移装置(440)包括第一图案形成部件(452)，
-提供载体材料(320)和覆盖材料(330)，所述载体材料(320)和覆盖材料(330)为至少一种基本平坦的材料纤维网；
-用于所述载体材料(320)的基本环形的载体支撑部件(470)，所述载体支撑部件具有与所述转移装置(440)的所述第一图案形成部件的图案相对应的支撑图案；
-载体材料保持部件(472)，所述载体材料保持部件用于暂时地将所述载体材料(320)附连到所述载体支撑部件(470)的基本环形的表面上，
-夹芯固定部件(495)，所述夹芯固定部件用于将颗粒材料和载体材料结合以便形成所述夹芯结构(300)，
执行以下工序：
-将所述颗粒材料(310)转移到所述转移装置(440)的所述接纳区域(442)，由此所述第一图案形成部件限定颗粒簇图案；
-将颗粒材料的所述颗粒簇图案移动到所述转移装置(440)的卸料区域(448)；
-将所述载体材料(320)以与转移装置的速度相对应的载体速度导引到所述载体支撑部件(470)上；
-通过所述载体材料保持部件(472)使所述载体材料(320)变形，
使得在所述载体支撑部件的未支撑区域内形成低凹(328)，由此形成与所述颗粒簇图案相对应的图案；
-从所述转移装置朝所述载体材料(320)排出所述颗粒材料(310)，
-将所述排出的颗粒材料(310)沉积在所述变形的载体材料(320)上；
-将所述覆盖材料(330)施用到所述载体材料(320)和颗粒材料(310)上，
从而形成夹芯结构(300)，
-提供固定部件(495)，以将覆盖材料和载体材料粘合在指定区域(360)中。
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