TWI479065B - 用於焊接終端紗線端的方法及用於提昇工業用織物之接縫強度的方法 - Google Patents

用於焊接終端紗線端的方法及用於提昇工業用織物之接縫強度的方法 Download PDF

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TWI479065B
TWI479065B TW097133880A TW97133880A TWI479065B TW I479065 B TWI479065 B TW I479065B TW 097133880 A TW097133880 A TW 097133880A TW 97133880 A TW97133880 A TW 97133880A TW I479065 B TWI479065 B TW I479065B
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Taiwan
Prior art keywords
seam
fabric
expander
welded
yarn
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TW097133880A
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English (en)
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TW200934927A (en
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John J Lafond
Jennifer L Bowden
Lynn F Kroll
Joseph Botelho
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Albany Int Corp
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Publication of TWI479065B publication Critical patent/TWI479065B/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9261—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools
    • B29C66/92651—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools by using stops
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/96—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
    • B29C66/961—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F1/00—Wet end of machines for making continuous webs of paper
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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Description

用於焊接終端紗線端的方法及用於提昇工業用織物之接縫強度的方法 發明領域
本發明有關利用已知稱為超音波間隙焊接的獨特超音波焊接技術形成單層機織物的織物接縫之技術。
參照併用
此處所參照的所有專利案、專利申請案、文件及/或參考文件皆合併於本文中以供參考、並可用來實施本發明。
 發明背景
造紙製程期間，藉由將一纖維性漿體亦即纖維素纖維的水性散佈物沉積在一造紙機的成形段中之一移動的成形織物上，藉以形成一纖維素纖維性網膜。大量的水經由成形織物自漿體被瀝排，而在成形織物表面上留下纖維素纖維性網膜。
新形成的纖維素纖維性網膜從成形段前進至一壓抵段，其包括一系列的壓抵軋縫。纖維素纖維性網膜穿過由一壓抵織物所支撐的壓抵軋縫，或如同常見地穿過兩個此等壓抵織物之間。壓抵軋縫之間，纖維素纖維性網膜受到壓縮力，壓縮力自其擠壓水且使網膜中的纖維素纖維黏彼此黏附以令纖維素纖維性網膜轉變成一紙頁片。水被一或多個壓抵織物所接受且理想上不會返回紙頁片。
紙頁片最後前進至一乾燥器段，其包括在內部由蒸汽加熱之至少一系列的可旋轉乾燥器筒或圓筒。新形成的紙 頁片藉由一乾燥器織物沿筒系列各者在一曲折路徑中被順序性導引，乾燥器織物將紙頁片緊密地固持抵住筒的表面。經加熱的筒經由蒸發將紙頁片的水含量降低至一理想位準。
應瞭解有時稱為造紙機布(PMC)的成形、壓抵及乾燥器織物皆在造紙機上採行無盡迴路的形式並以傳送器方式運作。應進一步瞭解造紙係為一種以顯著速度前進的連續製程。也就是說，纖維性漿體在成形段中被連續地沉積在成形織物上，而一新製成的紙頁片在離開乾燥器段之後被連續地盤捲於輥上。
單層機織物亦可形成為工程化織物。不論單層機織物是使用於包括但不限於藉由諸如紡黏或水刺纏結等製程、或諸如DNT皮帶或濘漿過濾皮帶或類似物等濕製程來製造非織造物、或用於紡織物光製皮帶之成形、壓抵、乾燥器、貫穿空氣乾燥(TAD)或工程化織物，接縫均勻度及完整度的性質皆很重要。
當織物受到機器方向(MD)拉力時，交織或互織以形成接縫之織物接縫終止部或紗線端係運行在一紙、TAD或其他工業用機器上時容易被拉回。為了盡量減少此接縫“拉回”，接縫中之紗線的終端端有時以一黏劑結合至一相鄰紗線。然而，黏劑未能完全抵抗機器運行條件，且隨時間經過仍容許發生拉回或紗線滑移。同樣地，利用具有諸如一PMC、TAD或工程化織物的縫紉終端端等其他強化手段之黏劑並未產生所想要的接縫完整度或均勻度。
此外，利用習知技術所形成如在MD中測量之接縫區域的寬度通常係譬如任意介於三點五至二十吋或甚至更大之間。基於許多原因，希望降低接縫面積。
第1(a－d)圖顯示與習知接縫形成技術相關之問題，其中兩織物邊緣的終止端係“重疊”於接縫區域中，且識別出臨界點12，其中這些端有可能在MD中“拉回”且該等端本身有可能突起經過紙側表面(第1a圖)。最後，由於織物中局部化應力增加使得重疊區域中之滑移如箭頭所示般增大(第1b圖)並具有一完全滑移且一孔16出現於織物的接縫區域中(第1c圖)。為此，接縫的重疊區通常被人工膠接所增強(第1d圖)以增加其強度；然而，膠接係為耗力且費時的製程。由於其低精密度，亦難以將膠水只限制於重疊紗線。此外，膠水終將因為織物的撓曲及/或磨刮而失效。
為此，需要具有不同或經改良之加強接縫紗線端終止、及因此產生的接縫強度之手段。
一可能用於加強織物用的接縫紗線端終止之技術係為諸如超音波焊接等焊接。超音波係指人類聽力範圍以上之音波，亦即>20,000 Hz，而超音波焊接係指材料以音波熔合。然而，不可接受的接縫形成係時常起因於諸如紗線過度融化、降低的接縫可滲透性、及由於局部化收縮導致織物中的扭曲等之超音波焊接。
在下列參考文件可發現其他接縫方法：美國專利案4,032,382有關一用於編接熱塑性單絲材料之方法及裝備。兩細絲在一裝備的一通路中被接合在一 起。其在通路中的側向壓力下曝露於高頻振動，其維度對應於細絲的原始直徑。結果係為一具有接近原始材料直徑之編接。
美國專利案4,401,137有關一具有一非標記迴路狀銷針接縫之成形織物，非標記迴路狀銷針接縫具有隨後可被超音波焊接以增加接縫強度之經修整“尾部”。
美國專利案4,501,782有關一用於以完全剛性方式接合邊紋式織物經紗端之替代性方法。經紗端被放在交錯指型位置中且以連續方式被超音波結合橫越織物。接縫接合部據稱在此操作後具有與織物主體部相同之卡徑(caliper)。
然而，對於造紙中的需求而言，此接縫由於造成紙中的標記及/或提供不平均的瀝排所以不可被接受。因為薄紙網膜很薄，如果此接縫使用於一TAD織物，有很高的紙網膜破裂風險。
美國專利案5,464,488有關一需以受控制式使用一超音波焊接裝備在兩塑料織物層之間形成一強固且撓性的結合之方法。紗線據說在此製程期間軟化但未融化且彼此束縛。該結合由於不脆而變得撓性且有效，因此不易具有先前技藝所提供的結合中之裂痕及破裂。
然而，此接縫在諸如TAD織物等開放結構中並不有效。比較像傳統接縫具有接近於織物主體部的性質之接縫對於效能而言係很重要。所提出的接縫係為那種經改良類型。
美國專利案5,571,590提供具有單層機基材元件的經疊 置端部分所形成的交叉機器方向(CD)接縫之造紙織物，其中端部分在一共同方向中延伸遠離端點；同時端點自端部分被截斷，且端部分沿著一共同切線被熔融結合。
美國專利案5,713,399提供藉由螺紋地盤捲比織物預定寬度更窄的一經織造織物條帶所製成之一PMC。條帶在至少一側向邊緣上具有交叉方向紗線的未結合端之一側向邊紋。此邊紋係位居相鄰彎圈的條帶之邊緣底下或上方。依此獲得的螺旋連續接縫被超音波焊接所關閉。
美國專利案5,731,063提供具有由一單層機基材元件端部分所形成的交叉機器方向接縫之造紙氈，其中端部分在一共同方向中延伸遠離該等端。同時端自端部分被截斷，且端部分沿著一共同切線被熔融結合，類似於美國專利案5,571,590。
美國專利案6,162,518係有關與專利案5,713,399類似之一經螺旋盤捲的PMC。熱結合被啟動之前，至少一連接線被放置在邊緣的突起線段上方。
美國專利案6,702,927有關螺旋盤捲比PMC預定寬度更窄的一經織造織物條帶所製成之一PMC。織物條帶具有第一及第二側向邊緣，分別沿其設有一第一及第二唇。各唇具有至少一織造於交叉方向紗線之長度方向紗線。一第一及第二間隙分別與第一及第二唇相鄰且位於其往內方向，第一及第二間隙缺乏長度方向紗線但其交叉方向紗線將唇接合至條帶體部。當螺旋盤捲時，唇鋪覆於相鄰彎圈的間隙以形成一可被超音波結合或其他手段所關閉之接縫。
公開的美國專利申請案2003/0221739係有關一在用於接合織物端的一銷針接縫中使用至少一預成形迴路或線圈以形成一無盡皮帶之PMC。基底織物端可藉由壓實、預擠壓及密封被預先及/或後處理以使端穩定化。亦可利用超音波融化或其他手段在經針織區域中增強及提供一平坦表面。
雖然超音波焊接具有優於諸如縫紉或膠接等習知接縫形成技術之數項優點，上述先前超音波焊接技術的特定缺陷係部份源自於習知超音波焊接以修改包括時間、能量及距離的多重參數為基礎之事實。因此，該技藝中仍需要一用於生成亦容易使用且可適用於廣泛範圍的織物類型之具有可接受的表面平坦度及強度的織物接縫之手段。
請注意此申請案中對於任何文件的引用及識別並未認可此文件可供作為本發明的先前技藝。
 發明概要
本發明有關一在諸如PMC織物、貫穿空氣乾燥器(TAD)織物、工程化織物、諸如傳送或韖製皮帶等用於紡織物光製製程的織物/皮帶等單層機工業用織物中生成接縫之方法。該方法包含此處描述為超音波間隙焊接之超音波焊接，其包含下列步驟：設定一擴能器與一鉆之間的距離、將待焊接材料放置在擴能器與鉆之間；及利用超音波能焊接該材料的一部分直到抵達阻止件然後在該間隙處以一預定時間長度繼續焊接而不進一步損失卡徑為止或吸收一預 定能量量值為止。
本發明之一目的係在紗線之間形成比起只用習知接縫方法更為強固之一致性結合。本發明之另一目的係在織物內形成更好的接縫完整度，其中被焊接的接縫區域在MD中比起一對應習知接縫中更窄，即便由膠接加強者亦然。
本發明之另一目的係形成一在MD中對於相同長度接縫具有一較強固及/或較耐久接縫之織物。較佳地，如MD中所測量的接縫寬度係為具有相等強度的一正常接縫或一利用習知技術所形成的接縫之寬度的一比例部分。此比例部分可為0.7或更低，較佳為0.5或更低，且最佳為0.3或更低。譬如，若“X”為根據先前慣例、或一習知接縫方法之MD中之一接縫的寬度，則根據本發明所形成之接縫寬度譬如係為0.7X或更低，較佳為0.5X或更低，且最佳為0.3X或更低但有相等強度。
本發明另一目的係使用本發明超音波間隙焊接技術來增強譬如用於諸如造紙機布、特別是乾燥器織物的工業用織物中之銷針接縫及直列式螺旋接縫。亦需要將MD紗線重新編織至織物體部中且因此可能由於紗線滑移及拉出而失效之銷針接縫也可藉由此處所述的超音波焊接技術受到改良。此等接縫中，形成接縫迴路本身之MD紗線可被焊接或熔合至CD紗線以防止其在使用中的操作拉力下拉出。
藉由消除習知超音波焊接相關的缺陷，本發明的超音波間隙焊接技術能夠達成具有充分強度之平坦的織物接縫且有助於藉由點焊或沿著織物終止端形成織物接縫。
本發明亦有關藉由超音波間隙焊接形成一織物接縫，其包含設定一機械阻止件以控制擴能器梢部與一鉆之間的一距離，對準一單層機接縫及接合式織物的終端紗線端，將經對準終端紗線端放置在擴能器與鉆之間的接縫中，將擴能器與鉆之間的距離調整至一固定預定間隙以及在該間隙距離以超音波能焊接織物的終端紗線端而不進一步損失紗線或織物卡徑歷時一預定時間長度或直到紗線吸收一預定能量量值為止。
本發明涵蓋一包含織物的接縫終端端超音波焊接之用於在織物中盡量減少終端紗線端拉回及接縫端終止磨耗之方法。
本發明亦有關一利用如此處所述具有極小或毫無經紗線重疊的方法將一織物的相鄰經紗線兩端對於彼此及/或對於其所跨接的CD紗線焊接在一起之方法。
圖式簡單說明
現在將參照圖式更詳細地描述本發明，其中類似的編號代表如下所識別之類似元件及部份。
第1(a)－1(d)圖描繪與習知接縫形成相關之問題；第2(A)圖顯示根據本發明的一實施例之一超音波間隙焊接的方法；第2(B)圖顯示根據本發明的一實施例之一超音波間隙焊接的方法；第3圖為利用根據本發明的一態樣之超音波間隙焊接所製備之織物的一範例； 第4圖為根據本發明的一實施例之一織物的橫剖視圖；第5圖為描繪接縫及互鎖位置的原理之圖式；第6圖比較一習知經膠接織物及根據本發明的一實施例之超音波間隙焊接所形成之不同互鎖長度的織物接縫之破裂強度；第7A及7B圖顯示使用本發明的一實施例時之接縫卡徑的保留及經改良的接縫強度。
 較佳實施例之詳細說明
本發明有關一在此處描述為超音波間隙焊接的超音波焊接之方法，包含下列步驟：譬如藉由設定一機械阻止件或利用其他手段控制一擴能器與一鉆之間的一距離來控制焊接的深度，將待焊接材料放置在擴能器與鉆之間；及利用超音波能來焊接該材料的一部分直到擴能器抵達預定深度或間隙然後以一預定時間長度繼續在該間隙距離焊接為止而不進一步損失紗線卡徑，或直到吸收一預定能量量值為止。
間隙焊接期間，可利用一機械阻止件(未圖示)來控制擴能器可對於鉆達到之最近距離。易言之，機械阻止件決定了超音波擴能器可穿透入被焊接織物中之深度。擴能器與鉆之間的此距離為間隙。一旦擴能器抵達一機械阻止件，其繼續以所指定時間或能量在該間隙焊接而不進一步損失紗線或織物卡徑。當施加超音波能時材料保持處於壓縮下。這可防止紗線崩塌且容許更多能量被放入焊接而無過 度焊接、卡徑降低、過熱且較不易造成諸如分子定向等紗線材料性質的損失。例如，若一織物卡徑為1.0 mm，一機械阻止件可被設定為在擴能器梢部與鉆之間留下一0.4 mm間隙。擴能器隨後將焊接至織物中0.6 mm。這可容許利用一時間或能量模式在焊接中具有能量量值增加。然而，任務在於控制擴能器的穿透深度或鉆的穿透深度。任一案例中，鉆與擴能器梢部之間的間隙係決定依此形成的焊接深度及焊接強度。亦必須將擴能器運動的振幅振動)列入考慮來計算間隙。
第2(A)圖顯示根據本發明的一實施例之超音波間隙焊接。因此，施加利用高頻超音波能來焊接織物之超音波擴能器10。使用一鉆20作為一支撐部件，其上放置有被焊接的織物30。以被焊接織物的卡徑厚度及需要的焊接深度為基礎將超音波擴能器10降低至一預定位準。第2(B)圖進一步描繪一使用於本發明的超音波焊接中之裝置。該裝置包含一超音波焊接器或該技藝中一般稱為超音波堆積體14(或聲學堆積體)者。堆積體14由三部份所組成，亦即轉換器22、升壓器24及擴能器26。一位於升壓器周圍之環28係為堆積體14被夾固於堆積體固持件25內之處。一機械阻止件15被設定為可防止堆積體固持件25或用於固持住升壓器的環或堆積體中立點之夾固件自一理想點產生任何進一步往下移動。當超音波焊接器為接通(ON)時，擴能器的梢部在此設定點上方及下方以特定振幅振動。然而，當超音波焊接器為關斷(OFF)時，則機械阻止件15係為設定擴能器10 與鉆20之間的一固定距離者。譬如，若部份1及2將被焊接在一起，阻止件15以部份的卡徑及理想焊接深度為基礎被設定至一預定高度。當堆積體14開始往下移動時，超音波梢部為關斷，且一旦擴能器接觸到樣本後，抵達一預定負荷值。譬如藉由安裝在堆積體殼體上之一諸如感測元件等壓力感測器來測量此負荷。在此點，超音波能被轉成接通。請注意在此點，堆積體殼體(此處以被夾固至其中之升壓器24的環28代表)尚未接觸到阻止件15。當焊接繼續時，焊接所產生的熱量合併擴能器在該等部份上之往下壓力係造成焊接區域中的材料卡徑降低直到堆積體殼體25碰到阻止件15為止，故防止紗線或織物卡徑之任何進一步降低。然而，超音波能係保持接通且繼續焊接。超音波能被轉成關斷之後，經焊接部份通常保持在壓力下一預定時間量使其能夠冷卻及固體化合併，故對於焊接區域提供諸如強度等經改良的物理性質。堆積體14隨後縮回，且間隙焊接完成。
利用時間、能量或距離來控制標準焊接。譬如，一旦已符合一特定觸發力，機器係焊接一設定時間量，或達到一設定能量量值，或往下至織物中一特別距離。超音波間隙焊接技術以一可接受紗線扭曲量產生一較強固結合並因為焊接的所有參數已經固定所以可容許織物全寬上的一致性焊接，亦添加另一控制度藉以產生一具有較大可接受加工條件窗口之遠為更堅固的製程。
本發明在生成一諸如PMC、TAD織物、工程化織物等單層機工業用織物、或一用於諸如軋光或皮革韖製皮帶等 紡織物光製製程的織物/皮帶中之一接縫方面具有特定應用。然而，可能具有其他應用。因此，第3圖中係為利用根據本發明的超音波間隙焊接技術所焊接之一織物30的一範例。焊接係發生於終止紗端端設置在織物的織造接縫內之處。部分織物具有10,000或更多個此等終端紗線端。織物30的橫剖視圖顯示於第4圖，其中顯示經焊接終端紗線端且亦顯示焊接至CD紗線。該處所焊接的織物30具有0.9 mm的卡徑且鉆與超音波擴能器之間的間隙設定為0.4 mm。從第3及4圖可觀察到本技術對於焊接製程提供精密度及卡徑均勻度。
擴能器與鉆之間的間隙亦取決於待焊接的材料。本發明的一實施例中，待焊接的材料係為一織物且擴能器與鉆之間的間隙為織物卡徑厚度的約30%至約55%。本發明的另一實施例中，擴能器與鉆之間的間隙為初始織物卡徑或厚度的約40%。可預見適合該用途之其他間隙距離。
請注意，在造紙機布中，初始織物厚度可介於從約0.5至3.5 mm之間。對於工程化織物，初始厚度可介於從約0.8 mm至6.0 mm之間或更大。
MD中各焊接的實際長度依據各互鎖區域中的平行關節數且亦依據經紗及緯紗維度及其密度(數量及間隔)而定，譬如第5圖所見。然而，這只示範接縫及互鎖位置的原理，實際圖案依據布的主體部中之編織圖案而定且終止點的可能分佈與其具有相關性。各焊接的寬度亦依據細絲直徑及經紗或MD紗線間隔而定。焊接可製成盡量小藉以維持 織物中且因此維持紙或其他所製造產物中之特徵。
因為TAD織物的本質，使用TAD織物係為藉由此處所揭露方法形成其一織物接縫之一較佳實施例。織物接縫未沿其本身被摺回；而是織物接縫就像一傳統單層機及經接縫織物者，其中織物紗線的終端端被織造於織物的相對端中，譬如不同於一銷針接縫式織物。
不論單層機織物是一TAD或工程化織物，接縫強度的性質及位於織物背側或機器運行側上之終端紗線端的區位及均勻度對於許多產物使用於其預定用途時係很重要。
根據本發明所形成的織物接縫終止可依據擴能器維度而具有任何長度及/或寬度。終止尺寸可隨著新產物、且亦包括目標在於使終止成為較短且MD中的接縫區域本身盡量地短之事實而改變。使用本超音波焊接方法之結果係為對於織物MD中的一相同長度習知接縫之一較強固及或較耐久的接縫。較佳地，如MD中測量之接縫寬度係為具有相等強度之一正常接縫或一利用習知技術所形成接縫的寬度之一比例部分。此比例部分可為0.7或更低，較佳0.5或更低，且最佳0.3或更低。譬如，若“X”為根據先前慣例或一習知接縫方法的MD中之一接縫的寬度，則根據本發明所形成的接縫之寬度譬如為0.7X或更低，較佳0.5X或更低，且最佳0.3X或更低但具有相等強度。
本發明的一實施例中，焊接只由各互鎖中的兩紗線終止所組成並在互鎖區中被局部化結合至CD紗線。
請注意諸如TAD織物等單層機織物及工程化織物通常 係包含單絲股或諸如聚酯、聚丙烯、聚醯胺(耐綸)及聚偏氟乙烯(PVDF)等聚合物的紗線。
一單層機織物中，接縫紗線端終止係如上述在機器運行條件下易受到拉回。在結合接縫紗線端終止中所用的標準黏劑亦可容許隨時間發生一特定程度的紗線拉回。超音波焊接比起標準膠接方法以兩或三倍更大強度來鎖固接縫端。一可接受的超音波焊接導致最多達55%的織物厚度降低及一強固結合。然而，可由於焊接一太大區域、紗線過度融化、及織物中的整體扭曲而產生不可接受的結果，故需要適當的參數。
請注意，此處所描述的超音波間隙焊接技術產生具有可接受扭曲量之一較強固的織物接縫。譬如，第7A圖顯示一TAD織物在一時間期間中之卡徑或厚度保留，處於使用一以時間為基礎的正常超音波焊接技術及本發明的一0.4 mm超音波間隙焊接技術之80%的擴能器運動振幅。第7B圖比較分別由兩技術所形成之兩織物的抗拉強度。第7A及7B圖顯示使用本超音波間隙焊接技術之經改良的接縫強度，其中因此保留織物卡徑或厚度且改良接縫強度。
請進一步注意本發明導致接縫紗線終止磨耗之降低。接縫終止因為其傾向於比織物平面突出更高所以常比織物體部更快地磨耗。藉由將終止帶領且保持於織物平面下方，此處所描述的超音波間隙焊接方法可有利地降低紗線終止易在織物體部之前磨耗的傾向。
此外，本發明涵蓋一用於盡量降低一包含超音波間隙 焊接的織物中之接縫終止端的終止接縫端拉回之方法。
本發明亦有關利用此處所述的方法來改良一接縫中的強度。超音波間隙焊接製程所形成的接縫係導致較短(在MD中測量)、較強固的接縫藉以譬如降低紙頁片標記可能性之優點，或防止會在薄紙/紙巾頁片中造成孔洞之終端紗線端移徙。
本發明亦有關改良接縫的完整度。譬如，當織物處於使用中，織物譬如運行於紙質薄紙或紙巾機器上時接縫區域務必維持其完整度。每個紗線端終止皆很關鍵且所提供的製程可以一預定圖案在特定地方被施用至特定紗線。由於該方法之故，可能使接縫紗線終止比起經膠接的紗線終止而言較不易受到失效。譬如，接縫紗線終止區域可依需要製成比原始織物具有更低的卡徑。維持織物接縫完整度係增加織物的有效運行壽命。雖然已經討論用於單層機織物之接縫，本超音波間隙焊接可施用至其他型接縫，諸如一銷針接縫，其中形成接縫迴路本身的MD紗線可被焊接或熔接至CD紗線以防止其在使用中於操作拉力下拉出，故改良接縫強度及應力或負荷分佈的均勻度。
現在將藉由下列非限制性範例進一步描述本發明。
範例
範例1
利用一40 KHz超音波間隙焊接器，一TAD織物以40微米振幅曝露於一500 ms焊接時間及一1秒固持時間(亦即，焊接之後擴能器在升高擴能器之前停留在焊接位置中1 秒)。接縫區域上的錶計壓力為144 kPa且觸發力(TRS)為111 N。
該製程的結果為一具有經加強接縫紗線終止之TAD織物(請見第3圖)，其在一造紙機上的一嘗試運行期間經歷極小的終端接縫紗線拉回。此外，TAD織物之所產生的接縫終止端導致比接縫膠接顯著更大的強度。
第6圖比較對於具有接縫之經膠接及經超音波間隙焊接的織物兩者之互鎖上的不同長度之一織物接縫的破裂強度。顯然，利用本發明的超音波間隙焊接所焊接之織物比起習知經膠接織物接縫者具有較高強度，特別是當接縫中的互鎖具有中等或短的經膠接MD長度時尤然。
因此，可瞭解本發明及其目的與優點，且此處已經詳細地揭露及描述較佳實施例，其範圍及目的不應因此受限；而是，其範圍應由申請專利範圍所界定。
1,2‧‧‧部份
10‧‧‧超音波擴能器
14‧‧‧超音波堆積體
15‧‧‧機械阻止件
20‧‧‧鉆
22‧‧‧轉換器
24‧‧‧升壓器
25‧‧‧堆積體固持件，堆積體殼體
26‧‧‧擴能器
28‧‧‧環
30‧‧‧被焊接的織物
第1(a)－1(d)圖描繪與習知接縫形成相關之問題；第2(A)圖顯示根據本發明的一實施例之一超音波間隙焊接的方法；第2(B)圖顯示根據本發明的一實施例之一超音波間隙焊接的方法；第3圖為利用根據本發明的一態樣之超音波間隙焊接所製備之織物的一範例；第4圖為根據本發明的一實施例之一織物的橫剖視圖；第5圖為描繪接縫及互鎖位置的原理之圖式； 第6圖比較一習知經膠接織物及根據本發明的一實施例之超音波間隙焊接所形成之不同互鎖長度的織物接縫之破裂強度；第7A及7B圖顯示使用本發明的一實施例時之接縫卡徑的保留及經改良的接縫強度。
10‧‧‧超音波擴能器
20‧‧‧鉆
30‧‧‧被焊接的織物

Claims (26)

  1. 一種在形成工業用織物之織物接縫期間用於焊接(welding)終端紗線端的方法，該方法包含下列步驟：將該終端紗線端放置在一超音波擴能器與一鉆之間；將該擴能器與該鉆之間的距離調整至預定間隙；及焊接該織物之接縫區域中呈預定圖案之特定接逢區域終端紗線端直至到達該預定間隙為止，其係藉由施加超音波能量及持續該焊接一預定時間長度或直到該等接縫區域終端紗線端吸收一預定能量量值為止來進行。
  2. 如申請專利範圍第1項之方法，其中該織物選自由下列各物所組成的群組：PMC織物，TAD，工程化織物，用於諸如軋光及皮革鞣製等紡織物光製製程之織物。
  3. 如申請專利範圍第1項之方法，其中該擴能器與該鉆之間的間隙係為該被焊接織物初始厚度的30%至55%之間。
  4. 如申請專利範圍第1項之方法，其中該織物為一單層機織物。
  5. 如申請專利範圍第1項之方法，其中該預定間隙藉由一機械阻止件所控制。
  6. 如申請專利範圍第1項之方法，其中該經焊接接縫區域比起在織物的MD中具有相等長度之一正常接縫或一利用習知技術所形成的接縫更為強固及/或更耐久。
  7. 如申請專利範圍第1項之方法，其中如MD中所測量的該接縫區域的一寬度係為具有相等強度之一正常接縫或利用習知技術所形成的一接縫的寬度之一比例部分，該比例部分為0.7或更低、較佳0.5或更低、且最佳0.3或更低。
  8. 如申請專利範圍第1項之方法，其中該接縫係為一銷針接縫或一直列式螺旋接縫。
  9. 如申請專利範圍第1項之方法，更包含下列步驟：決定焊接期間一擴能器與一鉆之間的一預定間隙。
  10. 如申請專利範圍第9項之方法，其中該織物選自由下列各物所組成的群組：PMC織物，TAD，工程化織物，用於諸如軋光及皮革鞣製等紡織物光製製程之織物/皮帶。
  11. 如申請專利範圍第9項之方法，其中該擴能器與該鉆之間的間隙係為該被焊接織物初始厚度的30%至55%之間。
  12. 如申請專利範圍第9項之方法，其中該織物為一單層機織物。
  13. 如申請專利範圍第9項之方法，其中該預定間隙藉由一機械阻止件所控制。
  14. 如申請專利範圍第9項之方法，其中該織物的終端紗線端係以最小經紗重疊被焊接在一起。
  15. 如申請專利範圍第9項之方法，其中該經焊接接縫區域比起在織物MD中具有相等長度之一正常接縫或一利用習知技術所形成的接縫更為強固及/或更耐久。
  16. 如申請專利範圍第9項之方法，其中如MD中所測量的該接縫的一寬度係為一正常接縫或利用習知技術所形成的一接縫的寬度之一比例部分，該比例部分為0.7或更低、較佳0.5或更低、且最佳0.3或更低。
  17. 如申請專利範圍第9項之方法，其中該等終端紗線端位於該織物平面以下。
  18. 如申請專利範圍第9項之方法，其中該接縫係為一銷針接縫或一直列式螺旋接縫。
  19. 一種用於提昇工業用織物之接縫強度的方法，該方法包含下列步驟：超音波焊接(ultrasonically welding)一織物接縫的呈預定圖案之特定接逢區域終端紗線端，其係藉由以一預定時間長度施加超音波能量或直到該等接縫區域終端紗線端吸收一預定能量量值為止來進行，該焊接係被控制在一擴能器與一鉆之間的一預定間隙下，該焊接係藉由施加超音波能量及持續該焊接並且同時限制該擴能器至該預定間隙的穿透深度以及確保該等終端紗線端位於該織物平面以下來進行。
  20. 如申請專利範圍第19項之方法，其中該織物的終端紗線端以最小經紗重疊被焊接在一起。
  21. 如申請專利範圍第19項之方法，其中該織物選自由下列各物所組成的群組：PMC織物，TAD，工程化織物，用於諸如軋光及皮革鞣製等紡織物光製製程之織物/皮帶。
  22. 如申請專利範圍第19項之方法，其中該擴能器穿透該被 焊接織物之初始卡徑或厚度的30%至55%之間。
  23. 如申請專利範圍第19項之方法，其中該織物為一單層機織物。
  24. 如申請專利範圍第19項之方法，其中該焊接接縫終止區域比起在該織物的MD中具有相同長度之一正常接縫或利用習知技術所形成的一接縫更為強固及/或更耐久。
  25. 如申請專利範圍第19項之方法，其中如MD中所測量的該接縫終止區域的一寬度係為具有相等強度之一正常接縫或利用習知技術所形成的一接縫的寬度之一比例部分，該比例部分為0.7或更低、較佳0.5或更低、且最佳0.3或更低。
  26. 如申請專利範圍第19項之方法，其中該接縫係為一銷針接縫或一直列式螺旋接縫。
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