MXPA98003142A - Product, apparatus and process for lamination in strips of a polymeric film, and unsheated fabrics or thread - Google Patents

Abstract

The present invention relates to a product, apparatus and process for lamination of a sheet of polymeric film (19) on a sheet of lightweight material (4). A sheet (4) of input material is divided into narrow fabrics (9), which can be folded by a fold guide (13), and can be separated by the use of rotating bars (12) and guides (56). The narrow tissues (9) then enter a station of enhancement or lamination (15). The process of rolling one of the two sheets that are of different widths, to allow the process to produce a supply for different final products. The laminate (21) of folded fabrics (9) and polymer (19) can be divided and / or split before being stored on a rewinder reel (3).

Description

PRODUCT, APPARATUS, AND PROCESS FOR LAMINATION IN STRIPS OF A POLYMERIC FILM, AND NOT YARNED OR YARNED FABRICS Background of the Invention The processes for laminating polymer films on separate narrow tissues are known. Relevant patents with respect to separate narrow tissue lamination include United States of America Patents Nos. 3,477,126, 3,656,513 and 4,859,259. The '126 patent discloses a method for manufacturing a strip conductive material, wherein the aluminum fabrics, which are separated on a roll, are unwound, and an extruder applies a layer of plastic material to one side of the fabrics . The broad extruded layer is subsequently divided to form individual aluminum weights, the plastic material covering a surface of the individual tissues, and hanging on both sides. Patent '513 discloses a method for manufacturing a strip material for making container bodies, wherein a single wide roll of cardboard is divided, polished, and coated by extrusion with plastic on both sides. Patent '513 shows revolving rods for directing the individual cardboard strips to subsequent manufacturing processes after the fabrics have been divided and laminated. Patent '259 discloses a process and apparatus for manufacturing re-sealable plastic bags, wherein a double set of interlocked closure strips is unwound from a reel, the strips are separated, and a polymeric film is extruded on the strips. strips Then the polymer film is divided; It is folded around a bender, and rolled onto reels. Processes for dynamically linking thermoplastic films are also known. U.S. Patent No. 4,919,738 incorporated herein by reference, teaches a method and apparatus for dynamically-mechanically bonding laminated layers, including at least one thermoplastic layer, by a pressurized pressure roller and an opposing roller.

Summary of the Invention An apparatus for in-line lamination of a first sheet and a second sheet, comprises a tissue splitter, for dividing the first sheet into a plurality of narrow tissues, a plurality of separate rotating elements for turning each of the t narrowed, in such a way that the plurality of tissues are separated by a predetermined distance, and a laminator to laminate the second sheet on a surface of the separated tissues, in order to provide a laminate of the second sheet and the tissues separated, and having a portion of the second sheet between the tissues, wherein at least one of the first and second sheets is a polymeric film. The present invention relates to a method and apparatus for laminating polymer with another material, wherein the polymer has a different width from the material to which it is laminated. One aspect of the present invention relates to a process and apparatus for laminating a wide non-spun fabric with narrow polymer strips. Another aspect of the invention relates to a process and apparatus for continuously performing the steps of dividing, folding, guiding, and laminating the fabric into a single unit. A single wide nonwoven fabric is divided, folded, separated by a predetermined distance by the use of rotating rods, and directed towards a subsequent rolling process. Depending on the spacing between the bent fabrics, each polymer strip may include a loose flap on either side, which may be suitable for forming a barrier fold in a diaper or other sanitary product. The spacing between the bent fabrics determines the width of a loose polymer fin that is formed. Yet another aspect of the invention relates to a process and apparatus for continuously performing the steps of dividing, separating, guiding, and laminating the fabric into a single unit. A single wide tissue is divided, it is separated by the use of rotating bars, and is directed towards a subsequent rolling process. This invention provides an apparatus and method for producing lamination in high speed production machines, at line speeds of approximately 1.52-6.10 meters / second (300-1,200 feet per minute (fpm)). This involves the on-line division of a single wide fabric of material, the turning, the separation, and subsequently the lamination of the tissues. More specifically, a fabric is unwound from a wide roll of non-spun material. The entrance tissue is divided into narrow tissues by marked division, tear division, knife division, laser, water jet division, or ultrasonic division.; the narrow fabrics, which can be folded into a fold plate, then move down the line to the rotating bars, which move from one another by a desired distance of separation of the fabric. Then the separated fabrics are guided to a station of enhancement or lamination, where the separated fabrics are fed through tightening rollers to adhere the molten or solid polymer to the fabrics. More specifically, the fabrics can be introduced into a roller tightening for extrusion lamination with a polymeric film, or they can be dynamically-mechanically linked to a solid polymeric film. When the non-spun film is laminated to a polymer extrudate, the extrudate is extruded into the clamp at a temperature greater than its refounding point to form a film. The compressive force between the fabrics and the extrudate in the tightening is controlled to link a surface of the fabric to the film in order to form the laminate. The wide laminated layer is then divided, and can be unfolded before being wound onto a rewinder reel. When a solid film of polymer is laminated, the film can be divided and separated, as described above, and then dynamically bonded to a wide nonwoven fabric. Other benefits, advantages, and objects of the invention will be further understood with reference to the following detailed description.

Brief Description of the Drawings' Figure 1 is a diagrammatic perspective view of an in-line apparatus for dividing, flipping, and separating a non-spun fabric, with subsequent extrusion lamination. Figure 2 is a diagrammatic perspective view of an in-line apparatus for dividing, bending, tumbling, and separating a non-spun fabric, with subsequent extrusion lamination. Figure 2A is a diagrammatic perspective view of a double bender apparatus of the present invention. Figure 3 is a schematic perspective view showing the combination of the rotating bar and the guiding mechanism. Figure 4 is a schematic perspective view of a bending bar used in the present invention. Figure 5 is a schematic perspective view of a decoupling bar used in the present invention. Figure 6 is a schematic perspective view of nonwoven fabrics folded after lamination to the polymeric film. Figure 7 is a schematic perspective view of a single non-spun strip, after the polymer film is divided, and after unfolding. Figure 8 is a diagrammatic perspective view of a folding apparatus of the present invention. Figure 9 is a diagrammatic perspective view of an in-line apparatus for dividing a polymer sheet, flipping and separating the polymer strips for lamination with a wide non-spun fabric.

Detailed Description of the Drawings It is a primary objective of this invention to provide a method and apparatus for forming a plurality of separate laminated strips of non-spunbond material and polymeric film, in high-speed production machinery. The laminated strips are characterized by being impervious to the passage of fluid, by virtue of the polymeric film, while maintaining a smooth feel on the fibrous surface of the laminate fabric. It is another object of this invention to provide a method and apparatus for forming a non-spun wide strip with a narrow strip of polymeric material laminated thereto. Another object of the present invention is to provide a product having a wide non-spun strip, with a narrow strip of polymeric material laminated thereto. In a first embodiment of the present invention, a non-spun fabric is used to provide an economical waterproof laminate having a smooth feel. In another embodiment, an elastic fabric fabric is used to provide the desired stretch qualities. In yet another embodiment, a polymeric fabric can be laminated to the polymeric film to provide a double polymer film laminate. Different degrees of vapor or air permeability in the laminate can be achieved, for example, by providing mechanical microvoids. In a preferred form, the laminate produced by the present invention has the desirable characteristics of soft feel, to have utility in a number of applications, including diapers, pads, sanitary napkins, or other products. In another form of the invention, the laminate of the present invention includes loose fins of polymeric material, suitable for use as a barrier fold. The polymeric film is preferably a thermoplastic polymer that can be processed into a film, for direct lamination by melt extrusion on the non-spun fabric in one embodiment. Polymers suitable for the film include polyethylene, polypropylene, poly (ethylene-butene), poly (ethylene-hexene), poly (etheno-oc-ten), poly (and ethylene-propylene), poly (styrene-butadiene). -styrene), poly (styrene-isoprene-styrene), poly (styrene-ethylene-butylene-styrene), poly (ether-ether), poly (ether-amide), poly (ethylene-vinyl acetate), poly (ethylene) methyl acrylate), poly (ethylene-acrylic acid), poly (ethylene-butyl acrylate), polyurethane, poly (ethylene-propylene-diene), ethylene-propyl-ene rubber. A new class of rubber-type polymers can also be used, and in general are referred to herein as polyolefins produced from single-site catalysts. Most preferred catalysts are known in the art as metallocene catalysts, wherein ethylene, propylene, styrene and other olefins can be polymerized with butene, hexene, octene, etc., to provide suitable elastomers to be used in accordance with. the principles of this invention, such as poly (ethylene-butylene), poly (ethylene-hexene), poly (ethylene-octene), poly (ethylene-propylene) and / or polyolefin terpolymers thereof. Suitable thermoplastic polymers can be biodegradable or environmentally degradable. A number of biodegradable thermoplastic polymers suitable in the practice of the invention are the normally solid oxyalkanol polymers, or the dialkanoyl polymers represented by poly (caprolactone) or poly (ethylene adipate); modified polysaccharides or polysaccharides such as starch-resin compositions that can be formed into a film. Suitable thermoplastic polymers that can also be environmentally degradable include polyolefin-based polymers that can be formed into a film, into water-insoluble and insoluble films, to be used as barrier materials in the manufacture of many useful articles, such as diapers, bearings, gaskets, curtains, and the like. Olefin-based polymers include the most common ethylene or propylene-based polymers, such as polyethylene, polypropylene, and copolymers such as ethylene-vinyl acetate (EVA), ethylene-methyl acrylate (EMA), and ethylene-acrylic acid ( EAA), or mixtures of these polyolefins. Polyolefins that can be polymerized alone or mixtures with other ethylenically unsaturated monomers include, for example, ethylene; propylene; 1-butene; isobutene; 1-pentene; halogenated olefins such as chloroprene; vinylbenzenes and naphthalenes, such as styrene or vinylnaphthalene; vinyl or vinylidene halides, such as vinyl chloride and vinylidene chloride; vinyl esters, such as vinyl acetate and vinyl benzoate; acrylic and methacrylic acids (otherwise known as polyacrylate or methacrylate) and esters or amides thereof; and dienes, such as butadiene, isoprene, and cyclopentadiene. Other examples of polymers suitable for use as films in the composite sheet of this invention are known, and are referenced in the relevant patents with respect to the extrusion lamination of non-spun fabrics, including U.S. Patent Nos. 2,714,571; 3,058,863; 4,522,203; 4, 614, -679; 4,692,368; 4,753,840 and 5,053,941 incorporated herein by reference. The fabric can be a fibrous nonwoven fabric comprising polyethylene, polypropylene, polyester, rayon, cellulose, nylon fibers and blends of these fibers. A number of definitions have been proposed for fibrous non-spun fabrics. The fibers are usually cut fibers or continuous filaments. As used herein, "non-spun fibrous tissue" is used in a generic sense to define a generally planar structure that is relatively flat, flexible, and porous, and is composed of cut fibers or continuous filaments. For a detailed description of non-spun yarns, see "Nonwoven Fabric Primer and Reference Sampler" by E.A. Vaughn, Association of the Nonwoven Fabrics Industry, 3rd edition (1992). The non-spun yarns can be loaded, linked by spinning, spread wet, spread in air, and melt blown, as such products are known in the trade. Alternatively, the fabric can be a spun fabric having elastic qualities, which can be imparted to the final rolled product. It is also possible to laminate a polymeric fabric to the extruded polymer in order to form a multilayer polymer laminate. The following examples illustrate the process of manufacturing the laminates of the present invention, and the processing machinery used in these methods. In light of these examples and this additional detailed description, a person of ordinary skill in the field will be able to see that variations thereof can be made without departing from the scope of this invention.

Example 1 A non-woven fibrous web of filled polypropylene with a density of 31.1 grams / m2 (26 grams / square yard) is loaded in the unwound position. Then the wide fabric is fed through the zero velocity thermal splicer, and is festooned and divided into a plurality of adjacent narrow fabrics. Then, at a line speed of 2.54 meters / second (500 feet per minute), the narrow tissues are separated by turning around the separate rotating bars. Then the tissue guides direct the narrow tissues towards the rolling station, where the fabrics are laminated by extrusion of a thermoplastic film of low density polyethylene, with a density of 0.914 grams / cubic centimeter, at 25.4 microns (1 mil. inch). The low density polyethylene film is extruded through a die at approximately 329 ° C (625 ° F), and into the tightening rolls, which press the fabrics and the low density polyethylene film to approximately 206.2. kPa (30 pounds per square inch). Then the thermoplastic low density polyethylene film is divided and folded on itself, and wound around the embobinator, for storage or for later use.

Use 2 In this example, the same procedures as in Example 1 are followed, with the exception that the plastic used for the extrusion is a DOW Chemical XU51800.51 elastomer Incite resin, with a density of 0.870 grams per cubic centimeter.

Example 3 A carded polypropylene having a density of 40.7 grams / square meter (34 grams / square yard) is loaded, divided, and separated as in Example 1, but at a line speed of approximately 5.08 meters / second ( 1000 feet per minute), and coated with ethylene-vinyl acetate copolymer at approximately 25.4 microns (1.0 mils). The ethylene-vinyl acetate film is extruded through a die at 260 ° C (500 ° F), and into the tightening rollers that press the fabrics and the ethylene-vinyl acetate film at 551 kPa ( 80 pounds per square inch).

Example 4 A nonwoven of carded polypropylene, having a density of 40.7 grams / square meter (34 grams / square yard) is loaded, divided, and separated as in Example 1, but at a line speed of about 3.81 meters / second (750 feet per minute), and coated with an ethylene-vinyl acetate copolymer at approximately 50.8 microns (2.8 mils). The ethylene-vinyl acetate film is extruded through a die at 299 ° C (570 ° F), and into the tightening rollers, which press the fabrics and the ethylene-vinyl acetate film at 68.95 kPa (10 pounds per square inch).

Example 5 A nonwoven of carded polypropylene, having a density of 49.0 grams / square meter (41 grams / square yard) is extruded with 50.8 microns (2 mils) of EPDM elastomer, at a line speed of approximately 4.32 meters / second (850 feet per minute). The EPDM film is extruded through a die at approximately 282 ° C (540 ° F) and into the tightening rollers, which press the fabrics and the ethylene-vinyl acetate film to approximately 275.8 kPa (40 pounds) per square inch).

Example 6 The DU PONT SONTARA grade 8,000 polyester fabric is extruded to 25.4 microns (1 mil) of DU PONT polyester elastomer (HYTREL 8260) at a line speed of approximately 4.83 meters / second (950 feet) per minute). The HYTREL film is extruded through a die at approximately 304 ° C (580 ° F), and into the tightening rollers, which press the fabrics and the HYTREL film at approximately 413.6 kPa (60 pounds per square inch) .

Example 7 The EXXON EXACT polymer type 4011 of ethylene and octene, manufactured by using a metallocene catalyst at a density of 0.885 grams / cubic centimeter, is laminated by extrusion to a SONTARA polyester fabric of DU PONT grade 8,000, to a line speed of approximately 3.56 meters / second (700 feet per minute). The EXACT film is extruded through a die at approximately 277 ° C (530 ° F), and into the clamping rollers, which press the fabrics and the ethylene-vinyl acetate film to approximately 344.7 kPa (50 pounds per square inch) . Example 8 A non-woven fibrous woven polypropylene carded fabric of 23.9 grams / square meter (20 grams / square yard) is loaded in the unwound position. The wide fabric of this unwound roll is then fed through the divider station to form multiple adjacent fabrics approximately 35.6 centimeters (14 inches) wide. Each fabric of 35.6 centimeters (14 inches) in width is then folded to approximately 8.89 centimeters (3.5 inches) from the free edges of the non-spun yarn to the center of the non-spun, so that both edges abut one another. The bent nonwoven fabrics are directed to the desired spacing from one another, ie, 0.635 centimeters (0.25 inches) wide, by the separate rotating bars, which are controlled by the tissue guides. The separated and folded non-spunbond fabrics are then fed to an extrusion lamination station, and are laminated by extrusion of a 0.914 gram / cubic centimeter polyethylene film. This polyethylene film, which has a thickness of approximately 20.32 microns (0.8 mils) is extruded through a conventional extrusion die, at a melting temperature of between 204 ° C and 316 ° C (400 ° F to 600 ° F), into the tightening rollers, which press the fabrics and the polyethylene film with a pressure of about 206.8 to 413.7 kPa (30 to 60 pounds per square inch), to achieve the desired bond strength from 3.94 grams / cubic centimeter (10 grams / inch) to several hundred grams / cubic centimeter (grams / inch) of separation resistance. Then the sheet enters a divider station, where dividers are located between the folded nonwoven fabrics, to divide the polyethylene film. In accordance with the above, the non-spun bent fabrics of 17.78 centimeters (7 inches) are all laminated in the polyethylene film of 18.42 centimeters (7.25 inches) in width. The non-woven fabric of 17.78 centimeters (7 inches) is laminated with polyethylene film, with a loose 0.3175 centimeter (0.125 inch) wide polyethylene film on each side of the non-spun, which is not laminated to non-spun . The laminated strip, folded, not spun, is rolled directly onto a roll for storage or for later use.

Example 9 The non-spun is divided and folded as in the Example 8. However, the spacing between each folded fabric is adjusted to approximately 10.16 centimeters (4 inches) in width. The divider knives are located between adjacent folded nonwoven fabrics, to divide the polymer into widths of 27.94 centimeters (11 inches). The result is a 35.6-centimeter (14-inch) wide non-woven fabric that is covered with a 27-inch-wide (11-inch) wide polymeric film, where the width of 17.78 centimeters (7 inches) of this film is laminated at 17.78 centimeters (7 inches) from the center of the not folded yarn. The additional 5.08 cm (2 inch) polyethylene film on opposite sides of the non-spun laminate, which is not laminated to the non-spun fabric, can be used to construct barrier folds, in order to provide a self-contained pouch for confine the waste of the body.

Example 10 A non-woven fibrous woven of carded polypropylene of 23.9 grams / square meter (20 grams / square yard) is loaded in the unrolled position. The wide fabric of this unwound roll is then fed through a divider station, to form multiple adjacent fabrics approximately 35.56 centimeters (14 inches) wide. Each fabric of 35.56 centimeters (14 inches) in width is then folded to approximately 8.89 centimeters (3.5 inches) from the free edges of the non-spun yarn to the center of the non-spun yarn, so that each edge meets one with the other. This fabric, 17.78 centimeters (7 inches) wide, is folded a second time at approximately 4,445 centimeters (1.75 inches) from the outer edge, in such a way that the bent edges meet one another. The bent nonwoven fabrics are then directed towards the desired spacing from each other, ie, at 0.635 centimeters (0.25 inches), by means of the separate rotating bars that are controlled by the tissue guides. The separated and folded non-spunbond fabrics are then fed to the extrusion lamination station, and are laminated by extrusion of a 0.914 gram / cubic centimeter polyethylene film.

This polyethylene film of approximately 20.32 microns (0.8 thousandths of an inch) is extruded through a conventional extrusion die, at a melting temperature of between 204 ° C and 316 ° C (400 ° F-600 ° F), into the tightening rollers, which press tissue and polyethylene film with a pressure of approximately 206.8 to 413.7 kPa (30 to 60 pounds per square inch), to achieve the desired bond strength of between 3.94 grams / centimeter (10 grams / inch) and several hundred of grams / centimeter (grams / inch) of separation resistance. The laminate then enters a dividing station, where the dividing blades are located between the folded nonwoven fabrics, to divide the polyethylene film. In accordance with the above, the non-spun bent fabrics of 8.89 centimeters (3.5 inches) are all laminated to the 9.525 centimeter (3.75 inch) wide polyethylene film. The folded nonwoven fabric of 8.89 centimeters (3.5 inches) in width is laminated with polyethylene film, with a loose 0.3175 centimeter (0.125 inch) width of polyethylene film on each side of the non-spun, non-laminated When not spun. The folded strip, and not spun, is then unfolded and rolled onto a roll for storage or later use.

Example 11 The non-spun is divided and folded as in Example 10. However, the spacing between each folded fabric is adjusted to approximately 5.08 centimeters (2 inches) in width. The knives are located between the adjacent folded nonwoven fabrics to divide the polymer into widths of 27.94 centimeters (11 inches). The result is a 35.56 centimeter wide non-woven fabric that is covered with a polymeric film 13.97 centimeters (5.5 inches) wide, where the width of 8.89 centimeters (3.5 inches) of this film is laminated to non-folded yarn of 8.89 centimeters (3.5 inches) in width at the center of the fabric. The additional polyethylene film of 2.54 centimeters (1 inch) on opposite sides of the non-spun laminate, which is not laminated to the spun np fabric, can be used to construct barrier folds, in order to provide a self-contained pouch, to confine the waste of the body.

Example 13 A non-woven fibrous woven of carded polypropylene of 23.9 grams / square meter (20 grams / square yard) is loaded in the unrolled position. A roll of polypropylene film is loaded in a second unrolled position. The polymer is unwound and fed through a divider station, to form multiple adjacent polypropylene strips of approximately 17.78 centimeters (7 inches) in width. Then the polypropylene strips are separated, by approximately 17.78 centimeters (7 inches), by separate rotating bars that are controlled by tissue guides. Then the wide spunbond is fed to the rolling station, and is laminated by pressure rollers in patterns to the separate strips of polypropylene film, at a pressure to achieve the desired bond strength anywhere between 3.94 grams / centimeter (10 grams / inch) and several hundred grams / centimeter (grams / inch) of separation resistance. Then the laminate enters a dividing station, where the dividing blades are located between the polyethylene film strips, to divide the non-spun material. The result is non-woven 35.56 centimeters (14 inches) woven laminates to the 17.78 cm (7 in) wide polyethylene film located in the center of the non-spun strip.

Example 14 A non-woven fibrous woven of carded polypropylene of 23.9 grams / square meter (20 grams / square yard) is loaded in the unrolled position. The wide fabric of this unwound roll is then fed through the divider station to form multiple adjacent fabrics approximately 2794 centimeters (11 inches) wide. Each fabric of 35.56 centimeters (14 inches) in width is then folded to approximately 5.08 centimeters (2 inches) from the free edges of the non-spun yarn, towards the center of the non-spinning. The bent nonwoven fabrics are directed to the desired spacing from one another, ie, 17.78 cm (7 inches) wide, by separate revolving bars that are controlled by tissue guides. The separated and folded non-spunbond fabrics are then fed to an extrusion lamination station, and are laminated by extruding a 0.914 gram / cubic centimeter polyethylene film. This polyethylene film, which has a thickness of approximately 20.32 microns (0.8 thousandths), is extruded through a conventional extrusion die, at a melting temperature of between 204 ° C and 316 ° C (400 ° F to 600 ° C). ° F), inward of the clamping rollers, which press the fabrics and the polyethylene film with a pressure of about 206.8 to 413.7 kPa (30 to 60 pounds per square inch), to achieve the desired bond strength between 3.94 grams / centimeter (10 grams / inch) and several hundred grams / centimeter (grams / inch) of separation resistance. Then the laminate enters a dividing station, where the dividing knives are located between the non-spunbond fabrics, to divide the polyethylene film. In accordance with the above, the non-spun bent fabrics of 17.78 centimeters (7 inches) are all laminated to the polythene film of 35.56 centimeters (14 inches) in width. The non-woven fabric of 17.78 centimeters (7 inches) is laminated with polyethylene film, with a loose fin width of 8.89 centimeters (3.5 inches) of polyethylene film on each side of the non-spun, which is not laminated to the do not spin The laminated strip, folded, not spun, is rolled directly onto a roll for storage or for later use. The product of Example 6 can be used as a polymeric backing sheet of a diaper, the folded portion of the non-spun yarn forming a leg fold of 5.08 centimeters (2 inches). In Examples 1-15 the polyethylene film can be replaced by a microporous formable film composed of 30 percent to 40 percent polyethylene, from 10 percent to 15 percent poly (ethylene-vinyl acetate) copolymer, from 40 percent to 55 percent calcium carbonate treated with stearic acid, and from 5 percent to 10 percent of monostearate glycerol. This non-spun fabric, with a central portion of the non-spun laminate to the above microporous formable film, can be stretched interdigitably in its CD and / or MD directions in the central portion of the laminated area, to form a microporous laminate in the central portion of the laminated area. This fabric does not spin. In accordance with the above, the product is a barrier to the fluid in the central portion, but is breathable to air, moisture, and moisture vapor, due to its high degree of microporosity.

The stretching method is detailed in the Patents of the United States of North America Numbers 5,296,184; 5,254,111 and 5,202,173 incorporated herein by reference in its entirety. In a preferred form, the laminated sheet employs a thermoplastic film having a caliper or a thickness between about 6.35 and 254 microns (between 0.25 and 10 mils), and, depending on the use, the film thickness will vary, and more preferably, in disposable applications it is of the order of about 6.35 to 50.8 microns (0.25 to 2 mils) in thickness. The non-spun fibrous webs of the laminated sheet typically have a weight of about 11.96 grams / square meter (10 grams per square yard) to 71.76 grams / square meter (60 grams per square yard), preferably from about 23.92 to 47.84 grams / square meter (from 20 to approximately 40 grams per square yard). As indicated above, the composite or laminate can be used in many different applications, such as baby diapers, baby training pants, catamenial cushions, clothing, and the like. The present invention allows to have a continuous process in line to introduce the woven material to the laminator, to enhance and laminate the strips or polymer zones to the non-spun in line, with a high efficiency. For simplicity, extrusion lamination and dynamic mechanical bonding are shown in the Figures, and are fully described in the specification; however, there are other possible lamination steps, including adhesive lamination, spray lamination, roll lamination, slot die rolling, ultrasonic lamination, or thermal bond lamination. As shown in Figure 1, two rolls of non-spun fibrous sheets 2, 3 can be loaded from 5.98 to 83.72 grams / square meter (from 5 to 70 grams per square yard) in the two-position unroller station 1 the four sheet it unrolls and feeds into the appliance. The end of a first roll 2 can be spliced with the principle of the second roll 3 by a zero-speed thermal splicer 5. Alternatively, the splice can be a tape splice at zero speed, or a splice tape splice. The sheet 4 is coupled with a festoon 6 if a splice at zero speed is desired. Then the sheet 4 is divided by the divider 8 into narrow fabrics 9. The narrow fabrics 9 are adjacent after division. The narrow tissues 9 are subsequently separated by the rotating apparatus and the tissue guides, which are separated in sequence down the longitudinal axes of the narrow input tissues 9. By controlling the separation of the tissue dividers, it is possible to obtain laminates having different widths of fabric, different widths of the final laminate, and uneven polymer hung from each side of the narrow tissue. The rotating apparatus is preferably a series of rotating bars 10 which lie in the plane of the narrow inlet weaves 9. The wovens are guided towards the station of enhancement and lamination 15 by means of the fabric guides 12. The guides of fabric 12, shown in detail in Figure 3, include a shore sensor 56 that optically detects the lateral deviation of the narrow tissue 9. The rotating rod 10 is fixed to a mounting plate 54 by linear bearings 50. The shore sensor 56 is linked to the actuator 52. Based on a signal emitted from the edge sensor 56, the actuator 52 moves the rotary bar laterally on the linear bearings, to compensate for any deviation of the narrow tissue 9. The enhancement and lamination station 15 includes the rollers 14, 16, an extruder 20, and a die 18, for extruding a sheet of polymeric film 19 onto the narrow fabrics 9. The polymeric film 19 and the narrow fabrics 9 are joined in tightening of rollers 14 and 16. Polymer layer 19 is extruded from die 18 'at a temperature of about 260 ° C to 329 ° C (500 ° F to 625 ° F). The extruded polymer film 19 is of the order of about 6.35 to 203.2 microns (0.25 to 8 thousandths of an inch) thick, and is rolled at temperatures in the range of about 260 ° C to 329 ° C (500 ° F to 625 ° F). The compression force in the tightening is controlled in such a way that the tissues are bonded to the polymer film. Pressures in the order of approximately 7.01 to 35.02 kPa (40 to 200 pounds per linear inch) are sufficient to achieve a satisfactory bond for fibrous tissues of approximately 5.98 to 83.72 grams / square meter (5 to 70 grams per square yard) . The resulting laminate 21 of polymeric film 19 and non-spun fabrics 9 is then tensioned between the separated rolls 22 and 24, such that the laminate can be divided by knives 26 to form the individual laminate fabrics 28. The laminate fabrics 28 include a single fabric of non-spun, spun, or polymeric material, with a polymeric layer adhered to one side of the fabric, and hung from the edges of the fabric. The hanging edges can then be folded back to produce a laminated layer the width of the non-spun fabric 9, with a polymeric film 19 adhered to one side. The narrow laminated fabrics 28 can then be wound in a winder 30 for storage or for future use. As shown in Figure 2, two rolls of non-spun fibrous sheets 2, 3 can be loaded from 5.98 to 83.72 grams / square meter (5 to 70 grams per square yard) in the two-position unrolling station 1. The sheet 4 is unwound and fed into the apparatus. The end of the first roll 2 can be spliced with the beginning of the second roll 3 by a thermal splicer at zero speed (as shown in Figure 1). Alternatively, the splice may be a tape splice at zero speed, or a splice tape splice. Sheet 4 will be coupled with a festoon if a splice at zero speed is desired. The sheet 4 is then divided by the divider 2, into the narrow tissues 9. The narrow tissues are adjacent after division. The narrow tissues 9 are subsequently folded by the bending apparatus 13, to form the bent fabrics 9A, and they are separated by a predetermined distance by the rotating apparatus 12 and the fabric guides 56, which are separated in sequence down the axes longitudinal of the bent tissues of entry 9A. By controlling the separation of the fabric dividers, it is possible to obtain laminates having different fabric widths, different widths of the final laminate, and uneven polymer hung from each side of the folded fabrics 9A.

The rotating apparatus is preferably a series of rotating rods 10 which lie in the planes of the input bent fabrics 9A. As described above with reference to Figure 3 the weaves are guided to the station of enhancement and lamination 15 by means of the fabric guides 56. The fabric guides 56, shown in detail in Figure 2, include a sensor edge 56a, which optically detects the lateral deviation of the folded fabric 9. The rotating rod 10 is fixed to a mounting plate 54 by linear bearings 50. The edge sensor 56a is linked to the actuator 52. Based on a signal emitted from the sensor of edge 56a, the actuator 52 moves the rotary bar 10 laterally on the linear bearings, to compensate for any deviation of the folded fabric 9. The station of enhancement and lamination 15 includes the rollers 14, 16, an extruder 20, and a die 18, for extruding a sheet of polymeric film 19 on the folded fabric 9A. The polymeric film 19 and the folded fabrics 9A are joined in the tightening of the rollers 14 and 16. The polymeric layer 19 is extruded from the die 18 at a temperature of about 177 ° C to 329 ° C (350 ° F to 625 ° C). ° F). The extruded polymer film 19 is of the order of about 6.35 to 203.2 microns (0.25 to 8 mils) in thickness, and is rolled at temperatures in the range of about 177 ° C to 329 ° C (350 ° F to 625 ° C). F) ~. The compression force in the tightening is controlled in such a way that the tissues are bonded to the polymer film. Pressures in the order of approximately 7.01 to 35.02 kPa (40 to 200 pounds per linear inch) are sufficient to achieve a satisfactory bond for fibrous tissues of approximately 5.98 to 83.72 grams / square meter (5 to 70 grams per square yard) . The resulting laminate 21 of polymeric film 19 and bent nonwoven fabrics 9A, is then tensioned between the separated rolls 22 and 24, such that the laminate can be divided by knives 26, to form the individual laminated fabrics 28, which are wound in the winder 30. The laminated fabrics 28 of polymer and non-spun are shown in Figure 6 before division, and in the Figure 7 shows a single tissue after division. In Figure 2A a second embodiment of the present invention is shown. The narrow inlet fabric 9 is bent by a first bender 13, to form the folded fabric 9A, which can approximate half the width of the narrow fabric 9. The folded fabrics 9A are then folded by the second bender 13A, to form the double folded fabric 9B, which can approximate a quarter of the width of the narrow fabric 9. The folding and unfolding apparatus 13 is shown in detail in Figures 4, 5, and 8. After leaving the divider 9 , the narrow fabrics 9 contact a bending guide 60 and a double bar 64. In the bending guide 60 it is supported on the support bar 62. The bending plate 64 is supported by the bending plate holder 66. , shown in sections for clarity. The fold plate holder 66 extends along the longitudinal direction of the fold plate 64, and can serve as a guide to prevent overlap of the edges of the narrow tissue. In Figure 4, the narrow inlet fabric 9, shown in phantom, makes contact with the inner portion 60A of the fold guide 60. The lateral edges of the narrow tissue follow the contour of the guide 60, and move upwards and on the fold bar 64. The back portion 60B of the fold guide 60, forces the narrow tissue-free edges 9 against the fold bar 64. Before rolling the laminate 28 over the winder 30, the non-bent yarn can unfolding by means of the unfolder bar 68, as shown in Figure 5. During the unfolding, the folded fabric 9A of the entrance laminate 28 makes contact with the unfolder bar. Since the opposite fins of the folded non-spun 9A run along the increasing width of the unfolder bar, the un-spun material is unfolded. Figure 5 also shows the loose hanging polymer 19A, shown in phantom for clarity, of the extruded polymer 19. The material produced by the present invention includes a wide non-spun section 9, which is laminated by extrusion to a polymeric film. The figure 6 shows two strips of folded non-spun material 9A laminated to the polymeric film 19. The final product 28, after splitting and unfolding, is shown in Figure 7. The final product includes a non-spun strip 9 laminated to a portion of the polymeric film 19B, with the polymeric fins soles 19A on either side of the laminated portion 19B. Another embodiment of the present invention is shown in Figure 9. A roll 102 of non-spun fibrous sheet 104 is loaded in the unrolled position 101. The end of the roll 102 can be spliced with the beginning of a second roll (not shown) by a splice at zero speed or a flying splice. If a splice at zero speed is to be used, the fabric 104 should be fitted with a festoon 6 (as shown in Figure 1). A roll of a sheet of polymeric film 119 is loaded in a second unwinding position 118. The end of the polymeric film sheet 119 can be spliced with another roll by a zero velocity splice or handwheel, as discussed above. As an alternative, the polymer film sheet 119 can be extruded through an extruder 20 (as shown in Figure 1). The edges of the extruded film would be trimmed to the appropriate size before, or at, the divider station 108. The polymer is unwound and fed through a divider station 108 to form multiple adjacent strips of polymer 106. The polymer strips 106 are then separated by a predetermined distance, by means of the separate rotating rods 112, which are controlled by the fabric guides 156. The rotating rods 112 are similar to those shown in Figure 3. The wide nonwoven fabric 104 is fed then to the rolling station 115, and laminated by the heated press rolls 114 and 116, to the separate strips of polymeric film 106, at a pressure to achieve the desired bond strength. Then the laminate enters a dividing station 126, where the dividing blades are located between the strips of polymeric film, to divide the non-spun material. The resulting non-spun fabrics are laminated to the polymeric film at the center of the non-spun strip. The final product 128 is wound on the embossing reel, in the winding station 130. This product is similar to that shown in Figure 6; however, there are no loose polymer fins 19A on the outer edges of the laminated portion 19B.

Claims (40)

NOVELTY OF THE INVENTION Having described the above invention, it is considered as a novelty, and therefore, the content of the following is claimed as property: CLAIMS

1. An apparatus for in-line lamination of a first sheet, and a second sheet which comprises a knitting divider for dividing a first sheet into a plurality of narrow fabrics; a plurality of rotatable elements separated to rotate each of the narrow tissues, such that the plurality of tissues are separated by a predetermined distance, and a laminator for laminating the second sheet on a surface of the separated tissues, with in order to provide a laminate of the second sheet and the separated fabrics, and having a portion of the second sheet between the fabrics, wherein at least one of the first and second sheets is a polymeric film.

2. An apparatus according to claim 1, characterized in that the first sheet is a non-spun fabric, and the second sheet is a polymeric film.

3. An apparatus according to claim 1, characterized in that the first sheet is a polymeric film and the second sheet is a non-spun fabric.

4. An apparatus according to claim 2 or claim 3, characterized in that it also comprises an extrusion die to form the polymer film.

5. An apparatus according to claim as claimed in any of the preceding claims, characterized in that it further comprises a first plurality of bending elements for bending each narrow tissue.

6. An apparatus according to claim 5, characterized in that it also comprises a second plurality of bending elements 13A, for folding the folded fabric 9A that comes out from the first plurality of bending elements.

7. An apparatus according to claim 5 or claim 6, characterized in that it also comprises a plurality of splitters, located downstream from the laminator, to unfold the narrow tissues.

8. An apparatus according to claim 1 in any of the preceding claims, characterized in that the separation of the predetermined distance between the tissues is sufficient to form a fold for the leg of a underwear.

9. An apparatus according to claim 1, characterized in that the laminator is an extrusion laminator, an adhesive laminator, a spray laminator, a recording laminator, a slotted die rolling mill, an ultrasonic laminator, a thermal bonding laminator, or a dynamic-mechanical laminator.

10. An apparatus according to claim 1 in any of the preceding claims, characterized in that the rotating elements are equally separated.

11. An apparatus according to claim 1 in any of claims 1 to 9, characterized in that the rotating elements are unequally separated.

12. An apparatus according to claim as claimed in any of the preceding claims, characterized in that the rotating elements include elements for guiding the plurality of tissues toward the laminator.

13. An apparatus according to claim 1 in any of the preceding claims, characterized in that it also comprises elements for dividing the second sheet between the separated tissues.

14. An apparatus according to claim 13, characterized in that the dividing element is a marking divider, a tear divider, a knife divider, a water jet divider, and an ultrasonic divider.

15. An apparatus according to claim 1, further comprising an unwinding station for storing at least one roll of the first sheet.

16. An apparatus according to claim 15, characterized in that the unwinding station is a two-position unwinding station.

17. An apparatus according to claim as claimed in any of the preceding claims, characterized in that it also comprises an automatic splicing element.

18. An apparatus according to claim 17, characterized in that the automatic splicing element is a thermal splicer at zero speed, a belt splicer at zero speed, or a flying belt splicer.

19. An apparatus according to claim as claimed in any of the preceding claims, characterized in that it also comprises a rewinder reel for receiving the laminate.

20. A process for in-line lamination of a first sheet to a second sheet by the steps: dividing the first sheet to form a plurality of narrow tissues; separating the narrow tissues by rotating the tissues around a plurality of spinning elements of separate fabrics, and laminating the second sheet on a surface of the separated fabrics, in order to provide a laminate of the second sheet and the separated fabrics, which has a portion of the second sheet between the separated tissues, wherein at least one of the first and second sheets is a polymeric film.

21. A process according to claim 20, characterized in that it also comprises bending each narrow tissue before the rolling step.

22. A process according to claim 20 or claim 21, characterized in that the rolling step is performed by a mill selected from an extrusion mill, an adhesive laminate, a spray mill, a mill by recording, a slotted die-rolling mill, an ultrasonic rolling mill, a thermal bond rolling mill or a dynamic-mechanical rolling mill.

23. A process according to claim as claimed in any of claims 20 to 22, characterized in that it further comprises dividing the portion of the second sheet between the separated tissues.

24. A process according to claim 23, characterized in that the step of dividing is performed by a divider selected from a mark divider, a tear divider, a knife divider, a water jet divider. , and an ultrasonic divider.

25. A process according to claim as claimed in any of claims 20 to 24, characterized in that it further comprises winding at least one roll of the first and second laminated sheets.

26. A process according to claim 2 in any of claims 2 to 25, characterized in that it further comprises automatically splicing the end of the first roll of sheet material, with the beginning of a second roll of sheet material.

27. A process according to claim 26, characterized in that the step of automatic splicing is performed by a splicer selected from a thermal splicer at zero speed, a belt splicer at zero speed, or a belt splicer. steering wheel.

28. A process according to claim as claimed in any of claims 20 to 27, characterized in that the turning step also includes a guiding step.

29. A process according to claim as claimed in any of claims 20 to 28, characterized in that the polymeric film is a polyolefin film.

30. A process according to claim as claimed in any of claims 20 to 29, characterized in that the polymer is selected from polyethylene, polypropylene, and copolymers thereof.

31. A process according to claim as claimed in any of claims 20 to 30, characterized in that the polymer comprises an elastomeric polymer.

32. A process according to claim 31, characterized in that the elastomeric polymer is selected from poly (ethylene-butene), poly (ethylene-hexene), poly (ethylene-octene), poly (ethylene-propylene) ), poly (styrene-butadiene-styrene), poly (styrene-isoprene-styrene), poly (ether-amide), poly (ethylene-vinyl acetate), poly (ethylene-methyl acrylate), poly (ethylene-acid) acrylic), poly (ethylene-butyl acrylate), polyurethane, poly (ethylene-propylene-diene), and ethylene-propylene rubber.

33. A process according to claim as claimed in any of claims 20 to 32, characterized in that the polymer film has a thickness of the order of 6.35 to 254 microns (0.25 to 10 thousandths of an inch).

34. A process according to claim as claimed in any of claims 20 to 33, characterized in that the other of the first and second sheets is a non-spun fabric.

35. A process according to claim 34, characterized in that the non-spun fabric comprises fibers of polypropylene, polyethylene, polyester, cellulose, rayon, nylon and mixtures of two or more of these fibers.

36. A process according to claim 34, characterized in that the non-spun fabric comprises polyolefin fibers.

37. A process according to claim 29 or claim 36, characterized in that the polyolefin is derived from the polymerization of monomers selected from the group consisting of ethylene, propylene, styrene, butene, hexene, and octene and mixtures thereof.

38. A process according to claim as claimed in any of claims 34 to 36, characterized in that the non-spun fabric has a weight of approximately 5.98 to 83.72 grams / square meter (from 5 to 70 grams / square yard) and the lamination in line is driven from 2.54 to 5.08 meters / second (500 to 1000 feet per minute).

39. A product formed by the process of in-line lamination of a first sheet to a second sheet, in accordance with that claimed in any of claims 20 to 38.

40. A product in accordance with claim 39, characterized because the separation between the tissues is enough to form a fold for the leg.