TW505546B - High speed embossing and adhesive printing process - Google Patents

High speed embossing and adhesive printing process Download PDF

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Publication number
TW505546B
TW505546B TW089106541A TW89106541A TW505546B TW 505546 B TW505546 B TW 505546B TW 089106541 A TW089106541 A TW 089106541A TW 89106541 A TW89106541 A TW 89106541A TW 505546 B TW505546 B TW 505546B
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TW
Taiwan
Prior art keywords
adhesive
embossing
pattern
roller
fabric
Prior art date
Application number
TW089106541A
Other languages
English (en)
Inventor
Kenneth Stephen Mcguire
Stephan Gary Bush
Original Assignee
Procter & Gamble
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Publication of TW505546B publication Critical patent/TW505546B/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F19/00—Apparatus or machines for carrying out printing operations combined with other operations
    • B41F19/02—Apparatus or machines for carrying out printing operations combined with other operations with embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/10—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an adhesive surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00—Sheets
    • B05D2252/02—Sheets of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0733—Pattern
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0741—Roller cooperating with a non-even counter roller
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0741—Roller cooperating with a non-even counter roller
    • B31F2201/0743—Roller cooperating with a non-even counter roller having a matching profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0784—Auxiliary operations
    • B31F2201/0787—Applying adhesive
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1007—Running or continuous length work
    • Y10T156/1008—Longitudinal bending
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1007—Running or continuous length work
    • Y10T156/1023—Surface deformation only [e.g., embossing]

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Adhesive Tapes (AREA)
  • Making Paper Articles (AREA)
  • Printing Methods (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Laminated Bodies (AREA)
  • Ink Jet (AREA)
  • Coating Apparatus (AREA)

Description

505546 A7 ______B7 五、發明説明（1 ) — 發明領媸 本發明關於壓花並施加黏著劑至薄層織物之方法及裝 置。 發明背景 一種薄層材料，其壓力感應黏著劑薄層免於受到不慎之 接觸其氣^方法及裝置係詳示於漢米爾頓（Hamilton )及 馬怪爾（McGuire)在1997年9月2曰共同發表之us第 5，6 6 2，7 5 8號專利，其名稱為’’壓按時以可鬆開方式密封至 _ 目表面之複合材料及其製造方法”（C〇mp〇site Material Releasably Sealable to a Target Surface When Pressed Thereagainst and Method of Making)，漢米爾頓及馬怪爾 在1999年2月16日共同發表之U.S.第5,871，607號專利，其 名稱為π具有由可變形Standoffs保護物質之材料及其製造 方法 ’’（Material Having A Substance Protected by
Deformable Standoffs and Method of Making)，以及馬怪 爾，韋德爾（Tweddell)及漢米爾頓（Hamilton)在1996年11 月8日共同申請之U.S.第08/745,339號專利申請案，其名稱 為π三維防聚集薄層材料及其製造方法及裝置”彳几⑺^ Dimensional, Nesting-Resistant Sheet Materials and Method and Apparatus for Making Same)，漢米爾頓及馬怪爾在 1996年1 1月8日共同申請之U.S·第08/745,340號專利申請 案’其名稱為π改良之儲存包裝材料n (Improved Storage Wrap Materials)，上述專利皆為本案說明書所參考列舉 者。 -4- 本紙張尺度適用中國國家標準(CNS) A4規格(210 X 297公釐）
裝 訂
505546 A7 __________________ B7 五、發明説明（2 ) 雖然這些請案/專利中所揭示用以製造該材料之方法 及裝置皆適於製造相當小尺寸之材料，惟該方法及裝置之 特徵為設計速度受到限制。可用以製造該材料之方法及裝 置之最大操作速度受限於移動元件之尺寸及重量，施加於 可變形底層材料之加熱速度，施加作用力於底層使其變形 為所需構造之速度及/或施加黏著劑至底層及/或中間裝置 元件之速度。該方法及裝置之操作速度在商業尺寸材料之 製造成本上為一主要考量因素。 因此，製造該材料並以高速施加黏著劑之方法及裝置有 其必要性。 發明概要 本發明提供一方法，其在一較佳具體實施例中之步驟包 括（a)施加熱融黏著劑至以最初切線速度轉動之加熱滾 筒；（b )研磨黏著劑至較薄之厚度並使其加速經過複數個 相鄰加熱膠黏滾筒之間一連串之量測間隙；（c )施加黏著 劑至以一切線速度轉動之適合膠黏塗佈滾筒，該切線速度 大於最初切線速度；（d )施加黏著劑至與第二圖樣壓花滾 筒啣接之第一圖樣壓花滾筒，該第二壓花滾筒之圖樣與第 一壓花滾筒之圖樣互補，該壓花滾筒皆已加熱；（e)將薄 層材料織物以切線速度在第一及第二壓花滾筒之間通過以 便同時對織物壓花並施加黏著劑，以便在壓花之間形成一 黏=圖樣；（f)將織物自第二壓花滾筒處傳送至第一壓花 滾筒，（g )自第一壓花滾筒處將織物剥離；與（h )將織物冷 卻0 -5-
A7
i說概述 雖然本案說明書已日日放 惟下列較佳具體實施例^指出本發明之中請專利範圍， 明，其中相同之參數表/、附圖對本發明有更詳盡之說 >数表不相同之元件且其中： 概要顯示根據本發明之方法及裝置； 圖2為圖1裝置之部份 著劑傳送之步驟； 視圖，其揭示壓花滚筒之間黏 二為本發月適用〈非定型圖樣代表 相同"资磚"之平面視圖； x 圖4為圖3四個究嶂,,以較靠近配置揭示圖樣邊緣之匹配 性； 圖5概要顯示適用於本發明形成圖樣之方程式之參考尺 寸；與 - 圖6概要顯τ通用於本發明形成圖樣之方程式之參考尺」 寸。 $ 主要元件代號表 1 工作站1 9 加熱細孔模子 2 工作站2丨 10 裝置 3 工作站3 11 第一轉動滾筒 4 工作站4 12 膠黏量測/塗佈滾筒 5 工作站5 13 膠黏量測/塗佈滾筒 6 工作站6 14 黏著劑塗佈滾筒 7 工作站7 15 母壓花滾 8 工作站8 16 公壓花滾筒 -6-本紙張尺度適财s國家標準(ciiTI4規格(21〇X297公爱) 505546 A7 __— B7 五、發明説明（4 ) 17 壓力''滚筒 40 黏著劑 18 剝離滾筒 5 0 聚合織物 19 S -纏繞滾筒 60 黏著劑被覆之織物 20 圖樣 發明詳述 友法及裝罾 圖1概要顯示本發明之方法及裝置1 〇，該裝置基本上由 兩個匹配4壓花滾筒1 5及1 6，複數個膠黏量測/塗佈滾筒 11 -14，一壓力滾筒i 7，一剝離滾筒丨8以及一冷卻s ·纏繞 滾筒1 9所組成。壓花滾筒由銅材製成且其中具有蝕刻之匹 配壓花圖樣，其連鎖對通過其間之薄層材料織物壓花。具 有凹孔及接觸區域之滾筒係指壓花滾筒丨5 ,具有凸起塊及 凹陷區域之滾筒係指公壓花滾筒丨6。母壓花滾筒表面上具 有一可釋放之被覆層。膠黏應用/量測滾筒11-14以交錯方 式配置在平滑鋼材與橡膠被覆鋼材之間，膠黏系統中最後 一個滾筒之膠黏塗佈滾筒1 4 一般為橡膠被覆鋼材。壓力滾 筒1 7及剝離滾筒丨8亦為橡膠被覆鋼材，冷卻3_纏繞滾筒 由中2鋼材滾筒1 9所組成，其外側表面上具有可鬆開之被 覆層且冷卻劑流過該滚筒。該筒轉動方向在圖1中以箭頭 表示。 參見圖1，例如熱融壓力感應之黏著劑4 〇經由一加熱細 孔模子9擠壓在第一轉動滾筒1 1表面上，該模子經由一加 熱軟管以熱融供應系統加以支撐（該系統具有_加熱漏斗 及可變速之齒輪泵，其未在圖中顯示）。第一膠黏量測滾 本紙張尺度適用中國國家標準(CNS) A4規格(2i〇x 297公爱） 505546
洵1 1之表速度明顯的較薄層材料織物5 〇之正常切線速 度慢，該織物50係接受壓花及黏著劑被覆。圖丨中量測夾 C處為工作站1，2及3，其餘之膠黏量測滾筒之轉速 逐漸加快，因此膠黏應用夾壓處工作站4之速度才可匹 配。黏著劑40自膠黏塗佈滾筒14在工作站4處傳送至母壓 花滾筒15，之後利用滾筒15之表面移動至工作站5，再與 由公壓花滾筒1 6傳送至工作站5之聚合物織物5 〇組合。 聚合物織物5 0在工作站5處壓花並同時與黏著劑4 〇組合 形成黏著劑被覆之織物60。膠黏至滾筒15表面之織物6〇 以浓筒表面移動至工作站6 ,橡膠被覆壓力滾筒丨7在工作 站6處施加壓力至織物之膠黏部位。仍膠黏至母壓花滾筒 1 5之織物60移動至工作站7 ,其藉由一剥離滾筒丨8自母 壓花滾筒1 5處分離。最終黏著劑被覆織物6 〇在工作站8 處移動至冷卻S-纏繞滾筒丨9 ,織物在該處冷卻以增加其長 度。 黏著劑40僅施加至母壓花滾筒丨5之凸起區域，這點係 經由仔細的控制母壓花滾筒至工作站4之膠黏塗佈滾筒間 隙及凸起。這些滾筒之間的間隙控制使黏著劑覆蓋之橡膠 滾筒1 4僅施加黏著劑至凸起，其未將黏著劑擠入接觸區域 之間的凹陷中。 黏著劑塗佈滾筒1 4為橡膠被覆鋼材滾筒，該橡膠層以特 殊方法研磨％成約0.001英吋之TIR壓出間隙。夾壓處之 間隙以精確之楔形塊機械加以控制。橡膠被覆層係用以（i ) 保護母壓花滾筒1 5之被覆層免於受到金屬與金屬接觸之損 -8- 本紙張尺度適用中國國家標準(CNS) A4規格(210X297公愛) 505546 A7
傷以及（2 許膠黏塗佈滾筒可輕壓在母壓花滾筒上，因 此橡膠之變形可補償壓花滾筒及膠黏塗佈滾筒之實際壓出 間隙，其允許ϋ著劑均勻白勺分佈在母壓花滾筒纟接觸區域 上。 膠黏塗佈滾筒1 4係輕壓在母壓花滚筒丨5上使橡膠表面 之變形可補償壓花滾筒及膠黏塗佈滾筒之壓出間隙，惟該 變形未足以將黏著劑擠壓入母壓花滾筒15表面之凹孔中。 黏著劑元全的停留在母壓花滾筒1 5之接觸區域係必要的，-以防止黏著劑流到織物壓花頂面上，壓花頂面上之黏著劑 在織物作ii]之前所具有之黏性使壓花毀壞。 所使用之黏著劑彈性甚佳，其由靜止細孔模子9轉換為 完全切線速度將造成伸展及破壞或無法黏著在第一量測滚 筒上。為降低黏著劑之拉伸速度，先施加至轉速較慢之滾-筒’之後經過一連串之量測間隙（工作站1,2及3),黏著 j 劑研磨至相當薄之薄膜並以所需之切線速度加速。 ， 膠黏滾筒須研磨至精確之直徑及壓出間隙以保持黏著劑 量測及加速所需之準確中間滾筒間隙，一般之壓出間隙為 0.00005英吋丁IR。膠黏滾筒須在周邊處均勻的加熱並越過 加工方向以避免滾筒因加熱引起之變形。若為電子式加熱 滾筒，單一之加熱器失效時仍能形成足夠之壓出以防止黏 著劑均勾的印刷在織物上，此時電錶係用以顯示加熱器之 故障。經由軸承及滾筒軸桿所漏失之熱量將使滾筒變形， 其亦可防止均勻之黏著劑印刷。滾筒軸承塊須加熱以防止 在橫向加工方向中產生溫度梯度。 -9« 本紙張尺度適用中國國家標準(CNS) A4規格(210 X 297公釐)
訂
A7
母壓花滾'肩丨5包含一可鬆開之 > 域以及凹孔之間的表面。可鬆開之二，加至接觸區 允Uir最佳之黏著性與釋放性組合。被覆層須 / 《黏著劑（一般為300-350T)傳送至母壓花滾 (同-許黏著劑被覆聚 (般為16(M8(rF)鬆開。若可憨開之被覆層具有之黏著劑 不^ ’黏相無法自膠黏㈣滾筒傳送至母壓花滾筒，若 被覆f具有過多之黏著劑，吾人須以撕扯方式才 π瑕、，；<黏著劑被覆層織物自母壓花滾筒處移開。 —薄膜應f最高壓花溫度下壓花以形成卷曲高曲徑之壓 Π f允許膠黏薄膜織物以較小之剝離作用力即可自母壓 :匕來同處鬆開。然而’壓花滾筒之溫度須低於薄膜織物之 融點，故最終之膠黏被覆層織物具有足夠之張力自母壓花 滾筒處移開。在高速操作之成功條件中鬆 化溫度之間的平衡為一重要之參數。 ^ 一剝離滾筒可在不損壞薄膜之情況下協助最終產品自母壓 化來食處移開。由於薄膜織物膠黏至母壓花滾筒之表面， 在剝離點之作用力係相當的大。剝離滾筒將這些相當大之 作用力侷限在相當短之織物距離中，使織物之變形較小並 可控制剥離角度。最終產品之防止變形對一致之薄膜特性 相g重要並可防止薄膜具有過早形成黏著特性之區域。 公壓花滾筒與母壓花滾筒之間接合之程度須仔細的加以 控制以防止對滾筒或薄膜織物造成損壞。壓花滾筒之外側 表面係研磨至0.00005英吋TIR壓出間隙，該接合以具有精 -10-本紙張尺度適用中國國家標準(CNS) A4規格(210 x 297公釐) 五 、發明説明（8 之飞械加以控制’且壓花滾筒之接 〈取終曲徑，即壓花之最終高度。 耆專膜 要之標準為公壓花滾筒與母壓花滾筒之間的接人 :娜。：種有效之技藝係藉由影像姓刻製程形成一； :二且：用孩滾筒做為”主滾筒” ()以形成其他滾筒 ==影像。該設備之設計須能保持匹配壓花滾筒之: 壓化及膠黏浪同係個別加熱及控制，以便正確的栌制 者劑傳送溫度及壓花滾筒釋放溫度。 - 互補圖樣輪廓之匹配公壓花滾筒及母壓花滾筒能夠在壓 花及膠黏步驟中完全支㈣薄膜織物，以確保作用適合的 分佈在薄膜材料中。相對於熱形成或真空形成-薄膜:其 具有例如一開孔皮帶或輪鼓之開放式支撐構造且其中形成γ 凹孔之、.我物部位未加以支撐’完全支撐之織物在轉速增加 之情：下使織物變形但未造成損壞，因此生產速度較快。 在壓化步驟中同時施加黏著劑至薄膜將精確的在壓花之間 使黏著劑固定在織物底端部位上。 、黏著劑精確的控制，特別是施加至母壓花滾筒黏著劑層 厚度及均自性，在^速高品質產品之生產中為一重要考 i因素在相當慢之黏著劑累加情況中，黏著劑由滾筒至 滾筒傳送過程中厚度之些許變化將導致施加至壓花滾筒之 黏著劑覆蓋住間隙。在此同時，該變化使過多之黏著劑在 壓花滾筒之某些區域中，其污染滾筒中凹孔或黏著劑無法 完全傳送至織物在壓花滾筒上具有黏著劑。 -11 - 本紙張尺度適用中國國家標準(CNS) A4規格(210X^7公酱)一 裝- 訂 線 505546 A7 B7
五、發明説明（9 圖樣形成~~~ 圖3及4顯示一圖樣20，其形成之演算方式詳示在馬怪 爾（Kenneth S. McGuire)共同綠案申請之u s•第 0 9 / 2 8 8，7 3 6號專利申請案中，其名稱為，，非定型圖樣之接 合及擴張方法"，其為本案說明書所參考列舉者。由圖3及 4顯示瓷磚2 0在罪近時邊界處並無接縫。同樣的，若單一 圖樣或瓷碑之相對邊緣靠在一起，例如環繞著一皮帶或滾 筒包覆該圖樣，接縫無法由肉眼加以辨別。 此處所引用之術語"非定型的"係指所组成之元件並無可 辨別之組肩，規律性或方位，此定義係根據Webster,s Ninth New Collegiate Dictionary中所對應術語之定義。.在 此圖樣中，一元件相對於相鄰元件之方位及配置並無可預 測之關係存在於後續之元件上。 相反的，此處所引用之術語"陣列”係指組成元件之圖樣 具有規則性之群組或配置，此定義係根據Webster，S New Collegiate Dictionary中所對應術語之定義。在此陣列 樣式中，一元件相對於相鄰元件之方位及配置具有可預測 之關係存在於後續之元件上。 二維突起陣列圖樣之規律程度與織物聚集性程度有直接 的關連，例如在緊密堆積六邊形陣列均一尺寸及形狀之中 空哭起高度規律性陣列圖樣中，各突起為任一其他突起之 重覆。若非全部織物，該織物聚集區域之完成係藉由重疊 織物之間對準之變換或在任何方向中一突起間隙織物部位 之間對準之變換。雖然任何程度之規律性具有一定程度之 -12- _____ 本紙張尺度適用中國國家標準(CNS) A4規格(210X297公釐) 五、發明説明（10 :集：二較低程度之規律性展現出較低之聚集傾、向。因 &疋里<非規律性突起圖樣聚集程度甚低。 性起二維圖樣之三維薄層材料係顯現出… 術語，，同型性”以及其字根"同型的, 之均一幾何及構造特徵，此定義係報墟w '
New Coll · 我係根據 Webster,s Ninth
Ueglate Dlctionary中所對應術語之定義。兴 言，包括關於全部非定型圖樣之突起統計數目之預^定 區：：有對織物特徵上相同之統計值，其為突起面積、 二;度此全部突起壁部長度等。當均-性對織物表面為必 此-關連性相對於織物實體構造特徵係屬重要的， 性;，垂直於織物表面所量測之特徵，例如突起之防碾壓 =維突起之非定型圖樣具有其他優點，例如三維薄芦材 ΐ =料《平面中保有相對於織物特徵之等方向性，該薄 等、H料f面中係最初等方向性的。此處所引用之術 ;寺万向性的'，係指織物之特徵在材料平面所有方向中1 有:目同的程度’此定義亦係根據Webster，s Ninth Ne: egiate Dieti°⑽y中所對應術語之定義m受理論 之：制，此項定義在於非定型圖樣中三維突起之非規律： :向配置。相反的，方向性織物材料因方向變化之特徵且 :類似之方式，其依循材料非定型圖樣之導引。舉例： :’若最初材料為拉伸等方向性的，薄層材料在材料平面 中任何方向皆具有均一之拉伸特徵。 A7 A7
在物理意中之眇_此、 計上相同數目之突起型圖樣表示每單位長度具有統 H L 卜_°其他統計上相同之參數包本突 於織物平面方二哭起間平均總間隙等。相對 向特徵中統計上之相同。 …上相同係指織物方 別再陣列〈概念以強調陣列與非定型圖樣之間的區 別，由物理上”規律性”令Μ、 疋我 < 陣列表示在突起尺寸，形 狀’間隙及/或方位中之掘 %㈣、士祕 《規則性。因此，由圖樣中-已知 ’： ：泉具有統計上不同的值，其取決於直線伸展之 且t數為突起壁部數目’平均突起面積，突起間平均 、，《 Θ隙等，其具有在織物方向特徵中對應之差異。 在較佳之特定型圖樣中，含 八 對於織物之尺寸，形狀起非均—性係有關於其相 形狀万位以及相鄰突起中心之間的間 隙。未免於受到理論之限制，相鄰突起中心至中心間隙之 差異對降低正面至背面聚集之可能性扮演—重要之角色。 圖樣中突起中心至中心間隙之差異在物理上的意義係指相 對於全邵織物而言突起不同空間位置之間間隙的差異，因 此在-或多個織物重疊部位之間所發生之"匹配"可能性相 當的低’其係根據突起/間隙之位置。此外，$疊織物上 複數個相鄰秀起/間隙之間"匹配”的可能性皆相當的低， 其原因在於突起圖樣之非定型特徵。 在-冗全非定型®樣中，中心至中^間隙是不規律的， 至少在設計者所選定之範圍中，因此在織物平面任一已知 -14- 505546 A7
發明説明 角位置處最近突起發生之可能性皆相同。織物之其他物理 幾何特徵在圖樣邊界中亦非規律性的或至少非均一的，例 如突起側邊之數目，突起之角度，突起之尺寸等。然而， 在某些條件下相鄰突起之間的間隙並非一致及/或不規律 的，惟多邊形之形狀可相互連鎖使相鄰突起之間具有均— 之間隙。這點對本發明三維防聚集薄層材料之某些應用特 別有效，其詳示於后。
裝. 此處所引用之術語”多邊形”及其形容詞，，多邊形的，，係指 ^ 具有三或多個側邊之二維幾何形狀，因為多邊形一或兩個 側邊即可界定一直線，因此三角形，四邊形，五邊形，六 邊形等皆在術語”多邊形”範圍中，例如圓形，橢圓形等之 曲線形狀具有無限多個側邊。 訂
線 當描述非均一之二維構造，特別是非圓形，形狀及非均 — 一間隙之特徵時，吾人常利用，，平均”數量及/或”相同”數 ^ 1 °例如二維圖樣中兩物件之間直線距離關係，該處間隙 之基礎為中心至中心或個別間隙，”平均”間隙之術語可用 以描述所形成之構造。其他以”平均”術語描述之數量包含 物件所佔據之表面積比例，物件面積，物件周邊，物件直 徑等。對例如物件周邊及物件直徑之尺寸而言，非圓形物 件之近似值可由理論上相同之直徑產生，其常用於水力學 敘述中。 織物中三維中空突起之完全不規律圖樣理論上無正面至 背面之聚集’其原因為各截頭體之形狀及排列皆係唯一 的。然而，此一完全不規律圖樣之設計為相當耗時且複雜 -15-本紙張尺度適用中國國家標準(CNS) A4規格(210 X 297公釐) Α7 ---------- Β7 五、發明説明（13 ) '一"^ ------ 的設計，其可為製造一適當構造之方法。根據本發明之非 聚集特徵係藉由設計圖樣或構造與相鄰構造之間關係為特 別的，其如同構造之全部幾何特徵，但其中構造之精確尺 ，寸’形狀及方位並非一致的且不重€。此處所引用之術語 、非重覆的"係指在一界定範圍中任何兩位置處之圖樣或構 白不相同’雖然在界定區域或圖樣中可具有一或多個已 知尺寸及形狀之突起，其他非均—尺寸及形狀之突起事實 上可消除相同之突起群组存在於複數個位置處。所界定區 域中非均一之突起圖樣使全部圖樣中之突起群組與其他類 似之突起群組皆不相同。三維薄層材料之強度使環繞一已 知哭起i任何材料皆無明顯之聚集性，即使該突起本身重 疊在一相互匹配之凹孔上，其原因為環繞單一突起之其他 哭起之尺寸，形狀及中心至中心間隙皆不相同。
University of Manchester* 之戴維斯（Davies)教授已從事多 孔細胞陶瓷薄膜之研究，特別是已發展出此薄膜之分析模 式以便數學模式能模擬實際之功能。此項成果詳示於布勞 頓（J. Broughton)與戴維斯（G· A· Davies)所發表之，，多孔細 胞陶瓷薄膜：一種分析陽極氧化物薄膜構造之推測模式，， (Porous cellular ceramic membranes: a stochastic model to describe the structure of an anodic oxide membrane)，其刊 登於 journal of Membrane Science· Vol· 1 〇ό (1995)，第 8 9 至1 0 1頁，其為本案說明書所參考列舉者。其他相關之數 學模式技藝詳示於韋森（D· F. Watson)所發表之，’應用至 Voronoi多種型式之η維Delaunay鑲嵌裝飾計算方式，， -16- 本紙張尺度適用中國國家標準(CNS) A4規格(210 X 297公釐) 505546 A7 B7 五、發明説明（14 ) (Computing the n-dimensional Delaunay tessellation with application to Voronoi polytopes)，其子丨j 登於 The Computer IQ-Urnal, Vol· 24, (1 98 1)，第 1 6 7 至 1 7 2 頁，以及林姆（J· F. F· Lim)，賈克斯（X· Jia)，傑弗瑞利（R· jafferali)及戴維 斯（G· A. Davies)所發表之”描述多孔陶瓷薄膜構造之統計 模式（Statistical Models to Describe the Structure of Porous Ceramic Membranes)，其刊登於 Separation Science and 3^g_hnol〇gy，28(1-3)(1993)，第 82 1 至 8 5 4 頁，這兩項著作 皆為本案說明書所參考列舉者。 做為此項成果之一部份，戴維斯教授已發展出以界定範 圍之二維Voronoi鑲嵌裝飾為基礎之二維多邊形圖樣。在 此一方法中’其再次參考上述之著作，核心點置於預先設 定平面之任何位置，其數量等於最終圖樣中多邊形之數 目。一電腦程式自各核心點以相同之速度同時徑向，，成長，， 為一圓形’當成長面對相鄰之核心點時即停止，並形成一 邊界線。這些邊界線形成多邊形之邊緣，其交又點成為多 邊形之頂點。 雖然該理論背景有助於瞭解樣式如何形成及其特徵，上 述數值璺代步驟可將核心點向外發展至所需之範圍。因 此，為能迅速的完成此方法，一電腦程式係設計能執行這 些適當之邊界條件及輸入參數，並能提供所需之輸出。
形成根據本發明圖樣之第一個步驟為建立所需圖樣之尺 寸，舉例而言，若所需圖樣之尺寸為1〇英吋長及1〇英吋 寬，其係選擇性的形成一輪鼓或皮帶以及平板，之後X _ Y -17-
發明説明 座‘系統具有最大X尺寸（xmax)為10英吋，最大Y尺寸 (ymax)為10英吋，反之亦然。 在座標系統及最大尺寸皆設定後，下一個步驟為決定 核〜點之數目，其將在圖樣之界定邊界中形成所需之多 邊开7该數目為介於0至無限大之間的整數，其選定係取 決於最終圖樣中所需多邊形之平均尺寸及間隙。較小之多 邊形對應著較大之數目，反之亦然。一種決定核心點或多 邊开y適田數量之方法係計算須充滿構造之多邊形理論上均 一 t尺寸及形狀，若此圖樣係規律性六邊形3 0之陣列（參 見圖5 )’其尺寸D為邊緣至邊緣之距離，Μ為六邊形之間 的間隙，六邊形數量密度Ν為：
iV = 2VI 3(D+M)2 /利用此方程式可計算非定型圖樣核心點密度，該圖樣所 形成之多邊形平均尺寸近似理論六邊形（D )之尺寸。當核 ^點贫度已知時’該圖樣中所使用之核心點總數係藉由乘
裝- 訂 以樣式之面積加以計算，此範例之圖樣面積為8〇 in、 心下一個步驟需要一亂數產生器，技藝中任何已知之適 亂數產生器皆可加以利用，其包含需要一，，種子數，，或利 客覜決疋之起始值，例如年代時間。許多亂數產生器 提供介於0與1之間的數字，上一亂數產生器為本案說明 所引用。若結果可轉換為介於〇與丨之間的數字或利用適 轉換因+，具有不同輸出之產生器亦可加以利用。 一電腦程式係設計執行亂數產生器，用以形成許多亂 -18-
k 505546 A7 B7 五、發明説明（16 ) 所需之疊代「喪字為上述計算，，核心點”數字之兩倍。當數字 產生時’其他數4*乘以最大X尺寸或最大Y尺寸以形成X 及Y座標亂數對，其X值介於〇與最大X尺寸之間，其Y值 介於0與最大Y尺寸之間’這些值以（x，γ)座標對加以儲 存，其數量等於”核心點’’之數量。 本發明所示方法與前述馬怪爾等申請案所揭示之圖樣形 成方式不同。若樣式之左側邊緣與右側邊緣呈”網狀結構” ，即能夠”接合π在一起，寬度B之邊界係增加至丨〇英吋 正方形之右側邊緣（參見圖6)。所需邊界之尺寸取決於核 心點密度，核心點密度愈高則所需邊界之尺寸愈小。計算 邊界寬度Β之傳統方法係參考至圖5中所示理論規則六邊 形陣列。一般而言至少有三列六邊形須運用在邊界中，故 寬度之計算方式為： B = 3(D+H) 現在任一座“為（X ’ y )之核心點p，X < B，將複製於邊界 中成為另一核心點p’，其新座標為（Xmax + x，y)。 若前述方法係用以產生最終的圖樣，該圖樣將為不規則 的且具有較大之多邊形尺寸及形狀，其不適用於某些例 子。為能對形成”核心點”位置之不規律性狀況具有某種程 度之控制，一控制因子或’’限制性”須加以選定，其為冷 (beta)。該限制性限制了排除距離e ( exclusi〇n distance )中 核心點附近區域，該距離表示任何兩松鄰核心點之間的最 小距離，其計算方式為·· Ε ,—is -ίλπ -19 - 本紙張尺度適用中國國家標準(CNS) A4規格(210X 297公爱) 505546 A7 B7 五、發明説明（17 其中又（lamfda)為核心點之數量密度（單位面積之點數）且 /3介於0與1之間。 為了控制”不規律性程度”，第一核心點以上述方式配 置，之後決定/5，再由上述方程式計算E，在核心點配置 之過程中/3維持不變，故E亦為常數。對每個後續產生之 核心點座標（x，y)，該點距離之計算係利用其他已配置之核 心點。若此距離小於E，最新產生之（x，y)座標須加以刪除 並形成一組新的座標。此方法一直重覆直到N個核心點已 成功配置為止。在根據本發明之接合演算方法中，對X < B 之所有核心點而言，原始點P以及複製點p，皆須對其他核 心點再次確認。若P或P’與任一其他點之間的距離小於E， P及P 1皆須加以刪除並產生一組新的亂數座標（x，y)。 若/5 =〇，排除距離為0且樣式為完全不規律的。若^ =1 ’排除距離等於六邊形緊密配置陣列之最近距離。介 於0與1之間的石值可控制該兩極限值之間的”不規律性程 度丨丨。 為了形成該圖樣，瓷碑之左側邊緣與右側邊緣適當接 合，瓷磚之頂端邊緣與底端邊緣適當的接合，邊界係運用 在X及Y方向中。 ‘王部的核心點已計算元成並儲存時，Delaunay三角測 量術可做為形成最終多邊形樣式之前置步驟。本方法所使 用之Delaunay三角測量術為一較簡單但與前述理論模式中 自核心點疊代成長為多邊形之方法在數學上具有相同之功 能。執行三角測量術之目在於產生三個能夠形成三角形之 -20- 本紙張尺度適用中國國家標準(CNS) A4規格(210X 297公釐) 505546 A7
核心點， 為執行三 三個核心 區別，之 未用以界 座標比較 形中。若 中無其他 圓半徑及 過測試， 組0 囱此通過該三個核心點之圓形中 念w Τ辨其他核心點。 角術’―電腦程式係設計能形成任何可能之 中每個核心點以唯〜之整數代表以利 後汁异通過各组核心點之圓半徑及中心勒座標。 足特足三角形之各核心點座標與圓半後及中心點 ，以決足是否有其他核心點在三個點所形成之圓 廷些核心點组合所形成之圓形通過測試，㈣形 核心點，將三個點之代表數字，其ΜΥ座標， 圓〜X及γ座標加以儲存。若所形成之圓形未通 無任何結果須加以儲存且須計算下一個核心點 當Delaunay三角測量術完成時，接著執行二維鑲 嵌裝飾以形成最終之多邊形。為完成鑲嵌裝飾，做為
Delaunay三角形頂點之每個核心皆成為多邊形之中心，之 後將Delaunay三角形所界定之圓形中心點，其包含頂點， 以順時針方式依續連接構成多邊形輪廓。將圓形中心點以 順時針順序加以儲存，以便對全部之核心點而言儲存各多 邊形 < 頂點座標。在多邊形產生之過程中，由於無法界定 一元整之多邊形，圖樣邊界處之任—三角形頂點皆加以省 略。 若便於接合相同圖樣之複數個複製圖樣以形成一較大之 圖樣，由複製在計算邊界中核心點所形成之多邊形可限制 為圖樣之一部份，並與相鄰圖樣中相同之多邊形重疊以利 匹配多邊形間隙及記錄’如圖3及4所示，由複製在計算邊 -21 - 本紙張尺度適用中國國家標準(CNS) A4規格(21〇X 297公釐）
界中核心 完成後即可加 下鄰接。 形成之多邊形在三角形測量術及鑲嵌裝飾皆 以刪除，因此相鄰圖樣可在適當間隙之條件 根據本發明 面，其圖樣 織物之最初 之構造’包 一足夠之作 邊形最終樣 方式中做為 。若多邊形 一或多條與 相對應之多 、㊄二維輪廓相互連鎖之最終多邊形完成時， 、 連鎖、’罔狀輪廓可用以設計織物材料之表 足一、隹中芝突起底部之輪廓，該突起由平坦 材料所形成。為了自平坦織物最初材料成突起 括所而取終二維構造反向結構之適當構造承受 用力以便使最初材料永久變形。 由芫整的多邊形頂點座標資料檔案可得到多 2，例如藉由繪製直線，此圖樣可運用在傳統 金屬螢幕蝕刻製程之輸入圖樣以形成三維構造 =間須有較大之間隙，一電腦程式係設計增加 多邊形側邊平行之直線使寬度加大 邊形尺寸。 減少 ’惟技藝之各種 且其皆在本發明 雖然本文已揭示本發明特定具體實施例 變更及改良皆在本發明之精神與範疇中， 申請專利範圍中。 -22-

Claims (1)

  1. •一種高速〜壓花及黏合印花方法，其步驟包括： (a) 施加黏著劑至適合之加熱膠黏塗佈滾筒； (b) 施加該黏著劑至第一圖樣壓花滾筒，其與第二圖樣 壓花滾筒啣接，該第二圖樣壓花滾筒之圖樣與第一 壓花滾筒之圖樣互補；與 (c) 將薄層材料織物以一切線速度在該第一及第二壓花 淡筒之間通過以便同時對織物壓花並施加黏著劑至 2 織物，因此該黏著劑在壓花之間形成一黏合圖樣。, •根據申請專利範圍第1項之方法，其步驟另包括：/ (a) 施和黏著劑至滾筒； (b) 經過複數個相鄰膠黏滾筒之間一連_量測間隙將該 黏著劑研磨至較薄之厚度；與 x (c) 施加該黏著劑至適合之膠黏塗佈滾筒； •根據申請專利範圍第1項之方法，其步驟另包括： (a) 將該織物自第二壓花滚筒傳送至第一壓花滾筒；與 (b) 將該織物自第一壓花滾筒處剥離。 4. 根據申請專利範圍第1項之方法，其步驟另包括在壓花 後該織物冷卻。 5. 根據申請專利範圍第丨項之方法，其中該黏著劑為熱融 黏著劑。 6·根據申請專利範圍第丨項之方法，其中該滾筒已加熱。 7·根據申請專利範圍第1項之方法，其步驟另包括： (a)施加黏著劑至以最初切線速度轉動之滾筒； (b )加速經過複數個相鄰膠黏滾筒之間一連串量測間隙 -23- 本紙張尺度適用中國國家標準(CNS) A4規格(210X 297公釐） 505546 8 8 8 8 A B c D 「、申請專利範圍 將該黏著劑研磨至較薄之厚度；與 (C )施加黏著劑至以切線速度轉動之適當膠黏塗佈滾 筒，該切線速度大於最初切線速度。 8. 根據申請專利範圍第1項之方法，其中該黏著劑自一加 熱細孔模子處擠出。 9. 根據申請專利範圍第1項之方法，其中該第一圖樣壓花 滾筒為母壓花滾筒，該第二圖樣壓花滾筒為公壓花滚 10. 根據申請專利範圍第1項之方法，其中該第一圖樣蜃花 滾筒上具有一釋放被覆層。 -24 本紙張尺度適用中國國家標準(CNS) A4規格(210 X 297公釐)
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