CN100429346C - 将造纸机结构元件和工业织物彼此粘结的方法、以及由其制成的织物 - Google Patents
将造纸机结构元件和工业织物彼此粘结的方法、以及由其制成的织物 Download PDFInfo
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- CN100429346C CN100429346C CNB2003801081097A CN200380108109A CN100429346C CN 100429346 C CN100429346 C CN 100429346C CN B2003801081097 A CNB2003801081097 A CN B2003801081097A CN 200380108109 A CN200380108109 A CN 200380108109A CN 100429346 C CN100429346 C CN 100429346C
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Abstract
一种制造造纸机或工业用织物的方法,包括以受控方式将平均直径为10微米的聚合树脂材料液滴施加在基材预选的位置上,以此来点粘结纱线,将螺旋缠绕条带粘结至一起,或将织物各层粘结至一起。
Description
技术领域
本发明部分涉及造纸技术,具体地说,本发明涉及一种在造纸机上用于在其上造纸的织物,一般称之为纸机织物。本发明还涉及通过例如水刺法制造非织造物和非织造产品,具体地说,是涉及所谓的工业用织物,该非织造物在其上制成。更具体地说,本发明是关于通过将聚合树脂材料用作粘结剂,并以高度受控和精确的方式沉积该聚合树脂材料的方法,使这种织物的结构元件互相粘结,结构元件例如各纱线或分开的层。
背景技术
造纸过程中,在造纸机成形部,通过将纤维浆沉积到移动的成形织物上形成纤维素纤维网,纤维浆也就是纤维素纤维的水分散体。浆体中的大量水分通过成形织物排出,而纤维素纤维网则留在成形织物的表面。
刚形成的纤维素纤维网从成形部进入压榨部,压榨部包括一系列压榨压区。纤维素纤维网被压榨织物支撑,或者通常情况下位于两层这样的压榨织物之间,穿过压榨压区。在压榨压区中,纤维素纤维网受到压缩力的作用,该压缩力将水从网中挤出,并使网中的纤维素纤维彼此粘附,使得纤维素纤维网转变为纸幅。水由一层压榨织物或多层压榨织物所吸收,并且理想的情况是不回到纸幅中去。
纸幅最终进入干燥部,干燥部至少包括一个可转动的干燥转鼓系列或烘筒系列,这些转鼓或烘筒由蒸汽在内部进行加热。干燥织物引导刚形成的纸幅以弯曲路径依次绕行该系列中的每个转鼓,且干燥织物将纸幅紧贴在转鼓的表面。加热的转鼓通过蒸发作用使纸幅的含水量降低至所需的水平。
应该了解的是,成形织物、压榨织物及干燥织物在造纸机上都采取无端环(endless loop)的形式,并且都起到传送带的作用。应该进一步了解的是,纸幅生产是一种以相当快的速度进行的连续过程。也就是说,在成形部,纤维浆连续地沉积到成形织物上,而刚生产出的纸幅在离开干燥部后就被连续地缠绕到辊筒上。
现有织物以各种各样的形式设计而使用,以满足造纸机所需,该织物按照所制造的纸张等级安装在造纸机上。通常,织物包括机织或其它类型的底布。此外,如果是用于压榨部的织物,则压榨织物还具有一层或多层其中针刺有精细的、非织造纤维材料毛层的底布。底布可以使用单丝纱线、捻合单丝纱线、复丝纱线或捻合复丝纱线织成,并且可以是单层的、多层的或层合的。纱线通常由在造纸机织物技术领域中的普通技术人员为制造纸机织物而使用的合成聚合树脂中的任意一种挤出而成,例如聚酰胺和聚酯树脂。
机织底布本身可以采用许多不同的形式。举例来说,机织底布可被织成环形、或者先平织然后用机织接缝将其转变为环状形式。或者,机织底布可以由一种一般称为改进式环状织造的工艺来生产,其中底布的纬向边缘具有使用其纵向(MD)纱线所形成的缝合环。在此方法中,MD纱线在织物的纬向边缘之间连续地来回交织,在各边缘处折回并形成缝合环。以此方式生产的底布,在安装至造纸机时放置成环状形式,因此称之为机上缝合织物。为了将这种织物放置成环状形式,将其两个纬向边缘拉在一起,两边缘处的缝合环彼此交叉,再引导缝合销或缝合销线穿过由交叉的缝合环所形成的通路。
此外,机织底布还可通过下述方式层合而成:将一层底布放置于由另一层底布所形成的无端环内,并通过将短纤维毛层针刺穿透这些底布的典型方法,使其像压榨织物一样彼此连接。这些机织底布中的一层或多层可以为机上缝合类型。这是目前公知的具有多层基础支撑结构的层合压榨织物。无论哪种情况,织物是无端环的形式,或者可缝合成这种形式,其具有在纵向环绕测量的规定的长度,以及横向跨越测量的规定的宽度。已披露的还有各种材料的“组件”,然后将其以平行条带的方式螺旋或叠层;这些组件通过层合等技术制成。
现将述及工业处理带,层合结构物为纺织工业所公知。层合技术也用来制造造纸中所使用的辊套。一种现有技术的带仅由作为基材的非织造纤维材料构成。之前还披露了用作压榨织物的层合非织造物和作为带的支撑结构的多层挤出片材,层合非织造物的各层具有不同的性能,例如疏水性。另一个现有专利教导了不同材料类型的螺旋缠绕条带,以制成带的支撑结构。现有技术还教导了一种扩张薄膜(expanded film)以及窄的复合“条带”的基材。其它现有技术还包括以下内容:
美国专利3,042,568示出一种制造层合织物带的方法和装置。使用热箱和压力辊将多段塑料涂覆的织物粘结成叠层的整体带;美国专利3,673,023示出一种制造增强叠层的方法,用于需要高拉伸强度的带中。该带通过将连续的增强索螺旋缠绕铺设成大致在基底的侧缘之间延伸的一个或多个螺纹而制成。该带通过将顶层放置在缠绕体之上,然后热压使之固化以形成加固的带结构而完成;
美国专利4,109,543示出一种复合叠层。该叠层包括热熔型的热塑性材料,以及主要由短纤维构成的短纤纱所制成的机织物材料。它们通过热压互相结合而形成带;以及
美国专利5,240,531示出一种由芯元件和弹性叠层构成的环形传送带。各层一起通过压力装置,并由热压作用而粘结在一起。
在许多应用情况中,包括机织物、螺旋缠绕机织物或针织物条带所形成的织物(参见Rexfelt的美国专利5,360,656),层合织物都需要靠某些机构将纱线固定住或使该织物粘结在一起。以往通常将短纤维针刺穿过多层织物而使它们结合在一起。前述的其它方法则利用例如粘结或焊接技术。
本发明提供了另一种粘结的方法,并能使织物尺寸稳定。
发明内容
因此,本发明可用于造纸机的成形部、压榨部及干燥部中的任何织物,以及用来制造非织造产品的工业织物。同样的,这些造纸机或工业用织物包括采用无端环形式的基材。在一个实施例中,许多离散的不连续的聚合树脂材料沉积物沉积在织物纱线的交叉点处或交叉位置处。这些沉积物将这些点处的纱线粘结在一起,并使该织物具有尺寸稳定性。
离散的不连续的聚合树脂材料沉积物的预选位置,可以是织物某一方向的纱线通过另一方向的纱线之上或之下的地方。粘结可以发生在全部或仅部分交叉点处。
在另一个实施例中,预选位置可用来将螺旋织物条带的相邻各段互相接合。
在第三实施例中,粘结树脂的预选位置是由交叉纱线所形成的结节或其它位置处,这些结节或其他位置允许在其上进行加热或采取其他活化方式,使附加层粘结在基材上,以形成叠层。
附图说明
图1是用来根据本发明第一实施例制造造纸机和工业用织物装置的示意图;
图2是可在其上实施第一实施例的织物表面的平面图;
图3是在图2所示织物上实施第一实施例之后的织物平面图;
图4是图1所示装置用来实施本发明第二实施例时的示意图;
图5是在螺旋织物条带的各捻圈间接缝的一部分,按第二实施例粘结前的平面图;
图6是在图5所示的接缝部分上面实施第二实施例后,该部分的平面图;
图7是用于实施本发明第三实施例的底布表面的平面图;以及
图8是图1所示装置用于实施第三实施例时的示意图。
具体实施方式
如前所述,在本发明的第一实施例中,造纸机或工业用机织物中的纱线会在它们的交叉点处互相粘结。通常,织物由单丝纱织成,织物可为涂层带或某些其它的纸机织物的基材,并且可以是稀疏组织的织物,如果不依据本发明来互相粘结,则织物中的纱线会很容易由预定的位置偏移。
但更广泛来说,织物也可以是机织的、非织造的、螺旋链接的、MD或CD纱阵列的或针织的织物,由任何制造纸机织物、或用来制造非织造物和非织造产品的工业织物的各种纱线所构成,例如单丝纱线、捻合单丝纱线、复丝纱线和捻合复丝纱线。纱线可由本技术领域中的普通技术人员为此目的而使用的聚合树脂中的任意一种挤出而成。所以,可使用以下族的树脂:聚酰胺、聚酯、聚氨酯、芳香族聚酰胺、聚烯烃族的树脂,及其它树脂。
或者,织物还可依据共同转让的Rexfelt等人的美国专利5,360,656所示的方法,通过螺旋缠绕机织、针织或其他材料的条带来制成,该专利所教导的内容以引用方式并入本文。因此,织物包括螺旋缠绕的条状物,其中各螺旋捻圈由连续接缝与下一个捻圈接合,从而使该基材沿纵长方向形成环状形式。各螺旋捻圈的相互接合可依据本发明第二实施例而完成,下文将详述。
上述织物形式不应视为仅有的可能形式。任何在纸机织物及相关技术领域中的普通技术人员所使用的各种基材都可替代其而使用。
不论织物是何种具体形式,都会将其安装在图1示意性示出的装置10上,所以根据本发明的第一实施例,聚合树脂材料可以沉积在纱线互相交叉的点上,这些纱线可以是织造结构或例如MD或CD纱阵列的非织造结构中的纱线。
应该了解的是,基材在安装于造纸机上的过程中,可为环状形式或可缝成环状形式。因此,图1所示的基材12应理解为基材12的整体长度的较短部分。若基材12为环状形式,则最实用的方法是将其绕装在一对辊上,辊虽未示于图中,但为纸机织物技术领域中的普通技术人员所熟知。在此情况下,装置10设在基材12的两个走向中的其中一个上,最方便的是顶部走向上,基材位于两个辊之间。但是,不论是否为环状,在制造过程中优选将基材12置于适当的张力下。此外,为了避免松垂,在基材12穿过装置10时,可用水平支撑件从底下对其进行支撑。最后应注意的是,若织物12是环状的,则依据本发明的第一实施例来施加聚合树脂材料之后,需要将其反转而使内面朝外,从而使聚合树脂材料位于织物12的背面上。
现在更具体地参照图1,当实施本发明的第一实施例的方法时,织物12示为朝上的方向移动通过装置10,装置10包括一连串的可供织物12逐步通过的几个站。
各站描述如下:
1.可选的聚合物沉积站14;
2.成像/聚合物精确沉积站24;
3.可选的定形站36;以及
4.可选的研磨站44。
在第一站即可选的聚合物沉积站14中,压电喷头阵列16安装在横轨18、20上,该阵列可沿横交于织物12移经装置10的方向在轨道上移动,并可沿平行于织物12运动的方向在轨道间移动,如果需要提供适当的粘结,则可利用该阵列以重复方式将聚合树脂材料沉积到织物12上面或内部,而织物12静止不动。如果需要,可选的聚合物沉积站14在织物12上沉积聚合物树脂材料可比例如喷涂的常规技术完成的更为均匀。但应该理解,可选的聚合物沉积站14无差别的将聚合树脂材料涂覆在织物12的纱线上,以及纱线之间的间隔或空隙中。但并非所有的应用都需如此,因此在本发明中,此实施例和其它实施例中聚合物沉积站14的使用都是可选的。
但为了完备起见,压电喷头阵列16至少包括一个但优选包括多个单独的由电脑控制的压电喷头,各压电喷头发挥泵的作用,其动作构件为压电元件。若技术上许可,则实施时可利用多达256个压电喷头或更多喷头所组成的阵列。其动作构件为晶体或陶瓷,通过施加电信号使之物理变形。此变形能使晶体或陶瓷发挥泵的作用,在每次接收到适当的电信号时就会物理地喷出一滴液体材料。这样,使用压电喷头响应电脑控制的电信号来重复地供应所需材料液滴,从而以所需形状累积所需材料量的方法,通常称为“按需喷滴”法。
再参照图1,压电喷头阵列16由织物12的一边开始,或优选从由纵向延伸于其中的基准线开始,贯穿基材12进行纵向和横向移动,而基材12则静止不动,并将聚合树脂材料以标称直径为10微米或更大,例如50微米或100微米的极小液滴形式,沉积在织物12上。如果需要,压电喷头阵列16相对织物12纵向与横向的位移,及聚合树脂材料液滴通过阵列16中的各压电喷头的喷出沉积,都由电脑控制,使织物12的单位面积上施加有所需量的聚合树脂材料。此外,材料不仅可在与织物的移动方向横交的方向沉积,还可与其移动方向平行、与移动方向成螺旋,或以任何其它适合于此目的的方式沉积。
在本发明中,使用压电喷头阵列将聚合树脂材料沉积在织物基材12的表面之上或内部,聚合树脂材料的选择受下述要求所限制:在输出时,即聚合树脂材料在压电喷头的喷嘴内准备沉积时,其粘度应为100cps(100厘泊)或更小,从而使各压电喷头能以固定的液滴输出速度来提供聚合树脂材料。限制聚合树脂材料选择的第二个要求是,当其呈液滴状由压电喷头喷向织物12时,或喷到织物12上之后,就必须部分地定形,以免聚合树脂材料流动,并保持对聚合树脂材料的控制,以确保在喷到织物12上时能保持液滴的形式。符合这些要求的适用聚合树脂材料包括:
1.热熔性材料及湿气固化的热熔性材料;
2.基于聚氨酯及环氧树脂的两组分反应体系;
3.由聚氨酯、聚酯、聚醚和硅酮所衍生的反应性丙烯酸酯单体及丙烯酸酯低聚物组成的感光聚合物组合物;以及
4.包括丙烯酸树脂与聚氨酯的水性胶乳和水性分散物以及微粒填充混合物。
应该了解,聚合树脂材料沉积在织物12上或其内部后,必须固定在织物12上或其内部。而定形或固定该聚合树脂材料的手段取决于其本身的物理及/或化学要求。感光聚合物能通过光来固化,而热熔材料可通过冷却来定形。水性胶乳和分散物可先干燥后再受热固化,反应性***则通过加热来固化。因此,聚合树脂材料可通过固化、冷却、干燥或其任意组合方式来定形。
为了控制聚合树脂材料在织物12内的渗入及分布,即,将该材料控制并限制于织物12的所需体积内,必须将其适当固定。这种控制对防止织物12表面之下的渗渍与扩散是极为重要的。例如,这种控制可通过将织物12保持在一定温度而实现,这种温度会使聚合树脂材料在接触时快速定形。也可在具有一定开孔率的织物上使用某些材料来实现控制,这种材料具有已知或明确的固化或反应时间,因此聚合树脂材料还来不及扩散超出织物12的所需体积,就已经定形。
喷头沉积材料的精确度取决于沉积材料的尺寸和用量。使用的喷头类型和所施加材料的粘度也会影响所选择喷头的精确度。
当单位面积所需量的聚合树脂材料施加在横贯织物12的两根横轨18、20间的区段后,织物12就会纵向前进一段等于该区段宽度的距离,并重复上述过程来将聚合树脂材料施加在与之前已经完成区段相邻的新区段上。以这种重复方式,整个织物12的单位面积上都能具有所需量的聚合树脂材料。
可使压电喷头阵列16在基材12上通过一次或多次,以沉积所需量的材料,并制成所需粘结。
或者,压电喷头阵列16仍从织物12的一边开始,或优选从纵向延伸于其中的基准线开始,并相对于横轨18、20保持在固定位置,而织物12则在该阵列之下移动,重复地在各单位面积上施加任何所需量的树脂材料,以在环绕织物12的纵向条带中提供粘结。当该纵向条带完成后,喷头阵列16在横轨18、20上横向移动一段等于纵向条带的宽度的量,并重复上述过程,以将聚合树脂材料喷涂在与之前已经完成的条带相邻的新的纵向条带上。如果需要,以这种重复方式,整个织物12也能在各单位面积上得到所需量的聚合树脂材料。
在横轨18、20的一端设有喷头检查站22,可供检测压电喷头阵列16中各个压电喷头喷出的聚合树脂材料的流量。在此处,压电喷头会被净化及清理,以使任何有故障的压电喷头单元能自动恢复操作。
第二站,成像/聚合物精确沉积站24,是本发明中唯一的非选择性站,横轨26、28支撑数码相机30和压电喷头阵列32,相机可横贯织物12的宽度方向移动,修补喷头阵列可横贯织物12的宽度方向移动并可在两根横轨26、28之间相对于横轨纵向移动,而织物12保持不动。
数码相机30检查织物12表面的影像,以定位出用于粘结目的沉积材料的位置。例如,织物12某一方向上的纱线交织于另一个方向上的纱线之上的结节处可为定位点,或者在非织造纱线阵列中一根纱线与另一根纱线的交叉处,可为另一种定位点。实际表面与所需外观之间的比较,是通过与数码相机30配合操作的图案快速识别(FPR)处理器来完成的。FPR处理器将信号传给压电喷头阵列32,使聚合树脂材料沉积在所需位置处,以符合所需外观。在本发明的第一实施例中,聚合树脂材料以受控方式沉积在纱线上的交叉位置或结节形成处之上,并与各纱线邻接,使纱线在其交叉点处彼此粘结。与可选的聚合物沉积站14相同,在横轨26、28的一端设有压电喷头检查站34,以检测各压电喷头喷出的材料流量。在该处,压电喷头阵列32中的各压电喷头将会被净化及清理,以使任何有故障的压电喷头单元能自动恢复操作。
举例来说,图2是织物50表面的平面图,该织物由纵向纱52和横向纱54以相当稀松的平纹组织织成。在纵向纱52越过横向纱54,以及横向纱54越过纵向纱52的地方,都会形成结节56。因为间隙58较大,所以测量该织物的开孔率,可以想象,这些纵向纱及横向纱52、54会很容易偏离图2所示的理想位置,而使织物50多少会受损。
图3为织物50表面的平面图,示出在成像/聚合物精确沉积站24中将聚合树脂材料沉积于其上的方式。在各结节56的两侧上,聚合树脂材料60沉积在纵向纱52或横向纱54上并越过所形成的结节56,从而使两根纱线52、54在结节56所代表的交叉点处互相粘结。
在第三站,可选的定形站36中,横轨38、40支撑定形装置42,可能需要它来定形所使用的树脂材料。定形装置42可为热源,如红外线、热空气、微波或激光源;冷空气;或紫外线或可见光源,定形装置的选择取决于所用的树脂材料的要求。
最后,第四站即最后一站是可选的研磨站44,在该处对织物12表面上的树脂材料进行适当的研磨,以使其具有均一厚度。可选的研磨站44可包括具有研磨表面的辊,及设在织物12的另一面上的另一个辊或支撑表面,以确保研磨能形成均一的厚度。
在本发明的一个变化例中,可选的聚合物沉积站14、成像/聚合物精确沉积站24、以及可选的定形站36也可调整为根据螺旋技术来处理织物12,而不是如上所述的固定于横机器方向操作。在螺旋技术中,可选的聚合物沉积站14、成像/聚合物精确沉积站24、以及可选的定形站36都会从织物12的一边例如图1的左侧边缘开始,并逐渐地横越织物12移动,同时织物12会按图1所示的方向移动。各站14、24、36及织物12的移动速率都设定为能使成品织物中所需的树脂材料以所需的连续方式呈螺旋状沉积在织物12上。在此可替代方案中,由可选的聚合物沉积站14和成像/聚合物精确沉积站24所沉积的树脂材料,可在每次螺旋通过可选的定形装置42底下时,部分地定形或固定,并在整个织物12通过装置10处理后完全定形。
或者,可选的聚合物沉积站14、成像/聚合物精确沉积站24、以及可选的定形站36也可全部保持在彼此对齐的固定位置中,而织物12在其下移动,使成品织物中所需的聚合树脂材料可施加到环绕织物12的纵向条带上。当完成该纵向条带后,可选的聚合物沉积站14、成像/聚合物精确沉积站24、以及可选的定形站36横向移动一段等于该纵向条带宽度的距离,并在与之前已完成条带邻接的新的纵向条带上重复进行上述过程。以此重复方式,整个织物12可完全按需处理。
此外,在处理材料时,整个装置也可保持在固定的位置。应该注意的是,该材料并不需要是全宽度结构物,也可为例如在Rexfelt的美国专利5,360,656中所披露的材料条,然后再制成全宽度的织物,该专利所披露内容在此以引用方式并入本文。在完全加工后,条带可为未缠绕的,并将其卷在一组辊上。可收存这些成卷的织物材料,然后可采用例如刚刚提到的上述美国专利中的教导内容,来制成环状的全宽度结构物。
在这一点上,在本发明的第二实施例中,装置10用来将螺旋缠绕织物带的相邻捻圈互相粘结而形成环状织物。一种使用超声波焊接装置来实施此操作的方法由共同转让的Collette等人的美国专利5,713,399所披露,该专利所披露内容在此以引用方式并入本文。
更具体地,美国专利5,713,399披露了一种通过螺旋缠绕比织物所需宽度窄的织物条带来制造纸机织物的方法,以及依据该方法所制成的纸机织物。该织物条带包括纵向纱与横向纱,并且具有至少沿其一个侧缘延伸的侧向毛边,该侧向毛边由超出该侧缘延伸的横向纱的自由端所形成。当螺旋缠绕毛边条带缠绕时,一个捻圈的侧向毛边叠置于该条带的相邻捻圈之上或之下。各相邻捻圈的侧缘互相邻接。如此形成的连续螺旋接缝通过用超声波将之上或之下的侧向毛边焊接或粘结到织物条带上而闭合。
现在参照图4,其示出如之前图1所示的装置10,但已改装以实施本发明的第二实施例,其添加了第一辊62和第二辊64,它们互相平行并可沿箭头所示的方向旋转,机织物条带66以连续螺旋的方式由贮料辊68缠绕到第一辊62和第二辊64上。可以认识到,当织物条带66缠绕在辊62、64缠绕上时,必须以适当的速率沿第二辊64,即朝着图4的右侧,移动贮料辊68。
机织物条带66具有第一侧缘70和第二侧缘72。第一侧向毛边74和第二侧向毛边76分别沿第一侧缘70和第二侧缘72延伸到条带66之外,但未在图4中示出。
当机织物条带66绕着第一辊62及第二辊64螺旋缠绕时,其第一侧缘70与前一捻圈的第二侧缘72邻接来形成螺旋状的连续接缝78。现在参照图5,该图为接缝78的一部分在进行粘结之前的部分平面图,当第一侧缘70和第二侧缘72互相邻靠时,由横向纱80的自由端所形成的第一侧向毛边74延伸超出侧缘70,并叠置在机织物条带66的前一捻圈上。此外,当第一侧缘70和第二侧缘72互相邻靠时,由横向纱80的自由端所形成的第二侧向毛边76也会延伸超出第二侧缘72,并位于机织物条带66的下一个捻圈之下。
依据本发明的第二实施例,成像/聚合物精确沉积站24取代在美国专利5,713,399中所示出的超声波焊接装置,用来封闭螺旋状的连续接缝78。具体而言,数码相机30检查螺旋缠绕机织物条带66的表面在螺旋状的连续接缝78处的影像,从而确定叠置在机织物条带66的前一捻圈之上的第一侧向毛边74的横向纱80与其中的纵向纱82的交叉点的位置,并确定位于机织物条带66的下一捻圈之下的第二侧向毛边76的横向纱80与其中的纵向纱82的交叉点的位置。实际表面与所需外观之间的对比,通过与数码相机30配合操作的图案快速识别(FPR)处理器完成。FPR处理器将信号传给压电喷头阵列32,使聚合树脂材料沉积在使其与所需外观吻合的位置上。在本发明的第二实施例中,聚合树脂材料沉积在交叉点处的与叠置纱线邻接的下层纱线上,从而使该纱线互相粘结,由此使螺旋状的连续接缝78闭合。
图6为图5所示的部分接缝78在完成粘结之后的平面图。如图所示,通过利用成像/聚合物精确沉积站24将聚合树脂材料84沉积在与横向纱80邻接的纵向纱82上,使第一侧向毛边74的横向纱80粘结到下层的纵向纱82上。同样地,通过将聚合树脂材料84沉积在与纵向纱82邻接的横向纱80上,使第二侧向毛边76的横向纱80粘结到叠置的纵向纱82上。以此方式,螺旋状的连续接缝78通过成像/聚合物精确沉积站24来封闭。同样地,还可以用该装置使MD纱(或CD纱)阵列互相粘结。例如,MD纱阵列取代Rexfelt的材料条带喂入该装置中。然后压电喷头沿着重合纱线的长度,将树脂沉积到纱线之间的空隙中的精确、不连续位置处,而使纱线在该点处互相粘结。在将纱线阵列喂入该装置中时,压电喷头会横移至下一组MD纱线并持续如此操作,直到制成适当长度与宽度的织物为止。若有需要,随后压电喷头还可以通过多次以沉积更多的树脂。一段段的这种织物可收卷储存,以供之后用于制造全宽度织物或用作层合物的层。
在本发明的第三实施例中,装置10用来将一层织物与另一层织物层合。一种制造叠层的方法披露于共同转让的Paquin的美国专利6,350,336中,该专利所教导内容在此以引用方式并入本文。更具体而言,美国专利6,350,336披露了一种用于造纸机的压榨织物的制造方法,此方法包括使用热活化的粘结膜将顶部叠层材料带固接在底布上。顶部叠层材料可以是织造织物、非织造网、或热塑性薄片材料,并且无论如何,都有热活化的粘结膜粘结在其两面的其中一面上。顶部叠层材料带和热活化的粘结膜一起形成多组分带,其螺旋缠绕在底布的外表面上,且使该顶部叠层材料带具有热活化的粘结膜的一面呈封闭的螺旋状贴抵外表面,并通过加热和加压与其粘结。然后修整多组分条带延伸于底布侧缘之外的部分,并将短纤毛层针刺入并穿过由多组分条带所形成的顶部叠层,以使其固接在底布上。
依据本发明的第三实施例,成像/聚合物精确沉积站24可用来将热塑性聚合树脂材料施加在由底布一个方向的纱线交织于另一方向纱线之上所形成的结节上。
具体而言,数码相机30检查底布外表面的影像,以定位由底布一个方向的纱线交织于另一个方向的纱线之上所形成的结节的位置。其实际表面与所需外观之间的对比,通过与数码相机30配合操作的图案快速识别(FPR)处理器来完成。FPR处理器将信号传给压电喷头阵列32,将聚合树脂材料沉积在必须使其与所需外观一致的位置上。在本发明的第三实施例中,热塑性聚合树脂材料沉积在底布外表面的结节上。
图7为底布90的表面在该沉积操作后可呈现的平面图。底布90由纵向纱92和横向纱94以单层平纹组织织成,虽然如此,但应该理解,本发明的实施并不是仅限于这种组织。纵向纱92在其越过横向纱94的地方形成结节96。同样,横向纱94在其越过纵向纱92的地方形成结节98。结节96、98具有热塑性聚合树脂材料的涂层100,该涂层由成像/聚合物精确沉积站24精确施加在该处。虽然所示各结节96、98具有这种涂层100,但并非必须如此,例如仅在某些预选的结节96、98上涂覆涂层100,而不涂覆剩余的结节96、98,其也包括在本发明的第三实施例的范围内。
现在参照图8,和图4相同,该图也示出如之前图1所示的装置10,但已改装以实施本发明的第三实施例,其添加了第一辊62和第二辊64,它们互相平行并按箭号所示的方向旋转。底布90在其结节96、98上已涂覆有涂层100后,仍会保留套绕在第一辊62和第二辊64上,并且顶部叠层材料条带102由贮料辊68螺旋缠绕在该底布上,而形成封闭螺旋状。例如,顶部叠层材料条带102可以为织造物,非织造网眼,MD或CD纱阵列或热塑性薄片材料。在将顶部叠层材料条带102布设在底布90上之后,其通过定形站36底下,在本发明的第三实施例中,定形站36为热源,使结节96、98上的热塑性聚合树脂材料熔化,从而使顶部叠层材料条带102粘结在底布90上。然后底布90与条带102一起通过研磨站44底下,其作用如同辊,在热塑性聚合树脂材料再固化时将它们压在一起而使它们互相粘结。这种叠层本身可以是工业用织物。或者在需要时,可在一个或多个表面上施加针刺毛层。
虽然本发明根据其特定的具体实施例加以描述,但是对于本领域技术人员来说,可以容易地对上述实施方案进行多种修改和改进,或应用于其他领域,而不偏离本发明的目的、精神和范围。所有这些改动均在本发明权利要求范围内。例如,根据用途,需要使某些压电喷头沉积一种聚合树脂材料,而其它的喷头则沉积不同种类的聚合树脂材料。此外,虽然以上披露了用压电喷头在基材的预定位置上沉积材料,但以所需尺寸范围沉积材料液滴的其它装置也为本领域的普通技术人员所公知,或将来可开发出来,并且这些其他装置也可用来实施本发明。利用这些装置来实施本发明也在本发明权利要求范围内。
Claims (37)
1.一种造纸机或工业用织物的制造方法,所述方法包括以下步骤:
a)提供所述织物的基材,该基材具有在织造或非织造图案中的离散交叉位置处互相交叉的纱线;
b)在多个预选的离散交叉位置处,以受控方式将多个聚合树脂材料液滴沉积到所述基材上,以控制所沉积的聚合材料的纵向和横向尺寸、以及所沉积的聚合材料的量,由此使所述纱线在所述离散交叉位置处粘结在一起,从而使所述织物具有尺寸稳定性;以及
c)至少部分定形所述聚合树脂材料液滴。
2.根据权利要求1所述的方法,其中所述液滴具有10微米或更大的标称直径。
3.根据权利要求1所述的方法,其中步骤b)和c)在横向延伸贯穿所述基材的连续区带上依次进行。
4.根据权利要求1所述的方法,其中步骤b)和c)在纵向延伸环绕所述基材的连续条带上依次进行。
5.根据权利要求1所述的方法,其中步骤b)和c)螺旋环绕所述基材而进行。
6.根据权利要求1所述的方法,其中所述基材是织成的,以及在步骤b)中,所述基材上的所述预选的离散交叉位置是由所述纱线形成的结节。
7.根据权利要求1所述的方法,其中所述基材是非织造的,以及在步骤b)中,所述基材上的所述离散交叉位置为所述基材的横向纱通过纵向纱之上的交叉点、或纵向纱通过横向纱之上的交叉点。
8.根据权利要求1所述的方法,其中所述聚合树脂材料以随机图案或均一图案进行沉积。
9.根据权利要求1所述的方法,其中,在步骤b)中,所述聚合树脂材料通过压电喷头阵列来沉积,该压电喷头阵列至少包括一个电脑控制的压电喷头。
10.根据权利要求1所述的方法,其中步骤b)包括以下步骤:
i)实时检查所述基材的表面,以定位所需的离散交叉位置,并使所述聚合树脂材料在其上沉积。
11.根据权利要求10所述的方法,其中所述检查步骤通过与数码相机配合操作的图案快速识别FPR 处理器实时进行。
12.根据权利要求11所述的方法,其中所述的沉积步骤通过连接于所述FPR处理器的压电喷头阵列进行。
13.根据权利要求1所述的方法,其中所述聚合树脂材料选自由下列材料组成的组:
(1)热熔性材料及湿气固化的热熔性材料;
(2)基于聚氨酯及环氧树脂的两组分反应体系;
(3)由聚氨酯、聚酯、聚醚和硅酮所衍生的反应性丙烯酸酯单体及丙烯酸酯低聚物组成的感光聚合物组合物;以及
(4)包括丙烯酸树脂与聚氨酯的水性胶乳和水性分散物以及微粒填充混合物。
14.根据权利要求1所述的方法,其中所述定形步骤通过将所述聚合树脂材料暴露于热源、冷空气或光化性酸进行。
15.根据权利要求9所述的方法,其中所述压电喷头阵列包括多个单独的由电脑控制的压电喷头,以及,其中部分所述单独的由电脑控制的压电喷头沉积一种聚合树脂材料,而其它的单独的由电脑控制的压电喷头则沉积不同的聚合树脂材料。
16.根据权利要求1所述的方法,还包括对沉积在所述基材上的所述聚合树脂材料进行研磨的可选步骤,以使所述基材表平面上的所述聚合树脂材料具有均一的厚度。
17.一种造纸机或工业用织物,包括:
基材,其具有在织造或非织造图案中的离散交叉位置处互相交叉的纱线;以及
在预选的交叉位置处的多个离散的尺寸受控沉积物,包括一个或多个聚合树脂材料液滴,所述尺寸受控沉积物具有的纵向和横向尺寸由所述液滴的受控布置而限定,其中所述聚合树脂材料液滴在所述离散交叉位置处将所述纱线粘结在一起,从而使所述织物具有尺寸稳定性。
18.根据权利要求17所述的造纸机或工业用织物,其中所述基材由纵向纱与横向纱交织而成,以及,其中所述离散交叉位置是由所述纱线形成的结节。
19.根据权利要求17所述的造纸机或工业用织物,其中所述基材由纵向纱与横向纱通过非织造制成,以及,其中所述离散交叉位置是横向纱通过纵向纱之上的交叉点、或纵向纱通过横向纱之上的交叉点。
20.一种造纸机或工业用织物的制造方法,所述方法包括以下步骤:
a)提供所述织物的基材,该基材具有在织造或非织造图案中的离散交叉位置处互相交叉的纱线;
b)在多个预选的离散交叉位置处,以受控方式将聚合物树脂材料以液滴沉积到所述基材上;
c)至少部分定形所述聚合树脂材料;以及
d)将叠层材料放置在所述基材上,并使所述叠层材料在所述离散位置处与之粘结。
21.根据权利要求20所述的方法,其中所述液滴具有10微米或更大的标称直径。
22.根据权利要求20所述的方法,其中步骤b)和c)在横向延伸贯穿所述基材的连续区域上依次进行。
23.根据权利要求20所述的方法,其中步骤b)和c)在纵向延伸环绕所述基材的连续条带上依次进行。
24.根据权利要求20所述的方法,其中步骤b)和c)螺旋环绕所述基材进行。
25.根据权利要求20所述的方法,其中所述基材是织成的,以及在步骤b)中,所述基材上的所述预选的离散交叉位置是由所述纱线形成的结节。
26.根据权利要求20所述的方法,其中所述基材是非织造的,以及在步骤b)中,所述基材上的所述离散交叉位置为所述基材的横向纱通过纵向纱之上的交叉点、或纵向纱通过横向纱之上的交叉点。
27.根据权利要求20所述的方法,其中所述聚合树脂材料以随机图案或均一图案进行沉积。
28.根据权利要求20所述的方法,其中,在步骤b)中,所述聚合树脂材料通过压电喷头阵列沉积,该压电喷头阵列至少包括一个电脑控制的压电喷头。
29.根据权利要求20所述的方法,其中步骤b)包括以下步骤:
i)实时检查所述基材的表面,以定位所需的离散交叉位置,并使所述聚合树脂材料在其上沉积。
30.根据权利要求29所述的方法,其中所述检查步骤通过与数码相机配合操作的图案快速识别 FPR 处理器实时进行。
31.根据权利要求30所述的方法,其中所述的沉积步骤通过连接于所述FPR处理器的压电喷头阵列进行。
32.根据权利要求20所述的方法,其中所述聚合树脂材料选自由下列材料组成的组:
(1)热熔性材料及湿气固化的热熔性材料;
(2)基于聚氨酯及环氧树脂的两组分反应体系;
(3)由聚氨酯、聚酯、聚醚和硅酮所衍生的反应性丙烯酸酯单体及丙烯酸酯低聚物组成的感光聚合物组合物;以及
(4)包括丙烯酸树脂与聚氨酯的水性胶乳和水性分散物以及微粒填充混合物。
33.根据权利要求20所述的方法,其中所述定形步骤通过将所述聚合树脂材料暴露于热源、冷空气或光化性酸进行。
34.根据权利要求28所述的方法,其中所述压电喷头阵列包括多个单独的由电脑控制的压电喷头,以及,其中部分所述单独的由电脑控制的压电喷头沉积一种聚合树脂材料,而其它的单独的由电脑控制的压电喷头则沉积不同的聚合树脂材料。
35.一种造纸机或工业用织物,包括:
基材,其具有在织造或非织造图案中的离散交叉位置处互相交叉的纱线;
在所述离散交叉位置的多个离散的聚合树脂材料沉积物,其中,所述离散的沉积物由受控方式沉积的液滴组成,以及,其中,所述聚合树脂材料至少部分定形;以及
在所述离散位置粘结到所述基材的叠层。
36.根据权利要求35所述的造纸机或工业用织物,其中所述基材由纵向纱与横向纱交织而成,以及其中所述离散交叉位置是由所述纱线形成的结节。
37.根据权利要求35所述的造纸机或工业用织物,其中所述基材由纵向纱与横向纱通过非织造制成,以及,其中所述离散交叉位置是横向纱通过纵向纱之上的交叉点、或纵向纱通过横向纱之上的交叉点。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/334,249 | 2002-12-31 | ||
US10/334,249 US7022208B2 (en) | 2002-12-31 | 2002-12-31 | Methods for bonding structural elements of paper machine and industrial fabrics to one another and fabrics produced thereby |
Publications (2)
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CN1732301A CN1732301A (zh) | 2006-02-08 |
CN100429346C true CN100429346C (zh) | 2008-10-29 |
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CNB2003801081097A Expired - Lifetime CN100429346C (zh) | 2002-12-31 | 2003-11-06 | 将造纸机结构元件和工业织物彼此粘结的方法、以及由其制成的织物 |
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US (3) | US7022208B2 (zh) |
EP (3) | EP1581691B1 (zh) |
JP (1) | JP4660202B2 (zh) |
KR (1) | KR101212301B1 (zh) |
CN (1) | CN100429346C (zh) |
AU (1) | AU2003287547C1 (zh) |
BR (1) | BR0317750B1 (zh) |
CA (1) | CA2509223C (zh) |
ES (3) | ES2606608T3 (zh) |
MX (1) | MXPA05007188A (zh) |
NO (1) | NO20053700L (zh) |
NZ (1) | NZ540640A (zh) |
RU (1) | RU2334034C2 (zh) |
TW (2) | TWI328628B (zh) |
WO (1) | WO2004061199A2 (zh) |
ZA (1) | ZA200504721B (zh) |
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2007
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