CN102006846A - 用于制造层叠结构的方法和设备 - Google Patents

用于制造层叠结构的方法和设备 Download PDF

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Publication number
CN102006846A
CN102006846A CN2008801286668A CN200880128666A CN102006846A CN 102006846 A CN102006846 A CN 102006846A CN 2008801286668 A CN2008801286668 A CN 2008801286668A CN 200880128666 A CN200880128666 A CN 200880128666A CN 102006846 A CN102006846 A CN 102006846A
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China
Prior art keywords
layer
pore radius
stepped construction
welding step
pattern
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CN2008801286668A
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CN102006846B (zh
Inventor
M·费恩奎斯特
M·通德卡尔
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Aishirui Health and Health Co., Ltd.
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SCA Hygiene Products AB
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Application filed by SCA Hygiene Products AB filed Critical SCA Hygiene Products AB
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
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Landscapes

  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Vascular Medicine (AREA)
  • Animal Behavior & Ethology (AREA)
  • Epidemiology (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Veterinary Medicine (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Public Health (AREA)
  • General Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Textile Engineering (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Laminated Bodies (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)

Abstract

本发明涉及一种用于制造层叠结构(22)的方法，该结构用于吸收性物品如尿布、卫生巾、卫生护垫、失禁垫等且以多个材料层(6，7，8)为特征，包括至少液体可渗透的第一层(6)、构成吸水芯(7)的第二层(7)、和第三层(8)，所述层(6，7，8)都由具有特定孔隙半径(R1，R2，R3)的材料形成，所述方法包括：通过至少两个超声波焊接步骤(4；12)将所述材料层(6，7，8)粘合在一起；以及每个所述焊接步骤都提供超声波焊接图案(15；17)，每个所述焊接图案(15；17)由多个结合位点(16；18)所限定。根据本发明的方法包括提供用于通常形成整个吸收性物品的所述焊接步骤(4；11)；以及以使得至少整个层叠结构(22)具有多种孔隙半径的方式选择所述焊接图案(15；17)。

Description

用于制造层叠结构的方法和设备
技术领域
本发明涉及一种用于制造层叠结构的方法，该层叠结构用于吸收性物品如尿布、卫生巾、卫生护垫、失禁垫等且由多个材料层来限定，这些材料层包括至少液体可渗透的第一层、构成吸收芯的第二层、以及第三层，所述各层都由具有特定孔隙半径的材料形成，所述方法包括：通过至少两个超声波焊接步骤将所述材料层结合在一起；以及为每个所述焊接步骤都提供超声波焊接图案，每个所述焊接图案由多个结合位点所限定。
本发明还涉及一种用于制造层叠结构的设备，该层叠结构用于吸收性物品如尿布、卫生巾、卫生护垫、失禁垫等且由多个材料层来限定，这些材料层包括至少液体可渗透的第一层、构成吸收芯的第二层、以及第三层，所述各层都由具有特定孔隙半径的材料形成，所述设备包括：用于将所述材料层结合在一起的至少两个超声波焊接装置；每个所述超声波焊接装置被设置为提供由多个结合位点限定的超声波焊接图案。
本发明还涉及一种用于吸收性物品如尿布、卫生巾、卫生护垫、失禁垫等且由多个材料层来限定的层叠结构，这些材料层包括至少液体可渗透的第一层、构成吸收芯的第二层、以及第三层，所述各层都由具有特定孔隙半径的材料形成，通过为每个所述焊接步骤提供超声波焊接图案的至少两个超声波焊接步骤将所述材料层结合在一起来形成所述层叠结构，每个所述焊接图案由多个结合位点所限定。
背景技术
当今的吸收性物品如尿布、卫生护垫、失禁垫、训练裤等类似物品通常通过组合不同类型材料层和吸收性本体的方法和***来制造。
常规的吸收性物品通常被设计为分层的产品，包括面对穿戴者身体的液体可渗透顶层(如基于人造或天然纤维的无纺材料)、吸收结构(例如作为液体分布或液体转移层的纤维材料层以及吸收芯)、以及液体不可渗透底层(如面对穿戴者衣物的热塑性背层)。这些不同层可为单独的材料片或层叠结构的形式。
之前已知制造不同类型的由不同材料层(如不同的纤维层)构成的层叠品来用作上述类型的吸收性物品。这种物品的制造工艺通常包括不同的工艺步骤，其中层叠结构的各层通过不同类型的技术被彼此结合，如胶合、热结合或超声波结合。
胶合工艺基于以下过程：根据预定胶合图案对材料层施加粘合剂，接着将该材料层结合在另一材料层上。此外，在热结合工艺中，层叠品中的两层或更多层通过加热具有可热熔纤维的层中的热熔纤维而被连接。为此，这些层通过具有辊隙的设备被进给，该辊隙由被设计为具有特定结合图案的两个辊来限定。最终，超声波结合工艺包括在超声波变幅器(ultrasonichorn)与另一辊(通常为所谓的图案辊)之间进给两个或更多个材料层，这样它们用特定的结合图案结合在一起。所有这些上述技术对本领域技术人员来说都是已知的并且用于产生用于吸收性物品的层叠结构。
在当今的技术方面，对吸收性物品某些特性进行改进的需求不断。例如，这种物品具有最佳流体吸收性能是很重要的，这样才能实现极高程度的流体捕获。此外，用品必须被设计为具有极低的再湿感并且必须在使用中让穿戴者感觉干爽。这就意味着物品必须具有更好的流体扩散性能从而为使用者提供更好的舒适度。
提到现有技术，要注意，文献WO 00/02727教导了通过在前进的材料幅上超声波焊接材料片来制作材料层叠品的***和方法。WO 00/02727示出的***包括在其内所述材料片通过第一超声波变幅器被连接的第一超声波焊接站，以及其内所述材料片接下来通过第二超声波变幅器被固定于材料幅上的第二超声波焊接站。
此外，专利文献EP1216679公开了通过使用超声波焊接将各材料层结合在一起来制造由纤维材料层构成的层叠品的方法。特别地，EP1216679教导的方法包括两个步骤：即两个层以第一结合图案被超声波焊接在一起的第一步骤，随后两个互连的层被超声波粘合于第三层的第二步骤。第二结合图案与第一结合图案的不同在于具有不同的结合区域。
在EP 1216679中还公开了在带型尿布和失禁保护用品中带的刚性和稳定性方而结合图案是如何影响层叠品性能的。
发明内容
本发明的目的在于提供一种制造用于吸收性物品的材料层叠品的方法和设备，特别是提供一种相对于现有技术进行改进且具有最佳流体吸水性和相对较低程度的再湿感并且在使用中还让穿戴者感觉干爽的吸收性物品。
该目的通过本文起初提到的那种方法来实现，所述方法包括：提供用于形成通常整个吸收性物品的所述焊接步骤；以及以使得至少整个层叠结构具有多种孔隙半径的方式选择所述焊接图案。
本发明的目的还通过本文起初提到的那种设备来实现，其中超声波焊接装置被设置为提供用于形成整个吸收性物品的所述焊接步骤，其中以使得至少整个层叠结构具有多种孔隙半径的方式来选择所述焊接图案。
本发明的目的还通过本文起初提到的层叠结构来实现，该层叠结构通过其中形成通常整个吸收性物品的所述焊接步骤形成；并且其中以使得至少整个层叠结构具有多种孔隙半径的方式来选择所述焊接图案。
通过本发明可获得某些优点。首先要注意，通过在几个步骤中将各层焊接在一起，可能获得在层间具有不同结合图案的物品。由于多种孔隙半径，具有这种结构的物品将提供更好的排水和扩散性能。
通过本发明，还可在材料之间提供更好的接触，并且物品的结构更光滑，意味着物品的使用者可得到更好的舒适度。
与现有技术相比，由于领悟到上述超声波焊接步骤影响性能如吸收性物品中流体的排水和吸水性，本发明提供了对上述问题的解决方案。
根据一个实施例，本发明优选被设置为通过将各材料层以某种方式结合在一起形成通常整个物品，该方式包括将第三层和第二层结合在一起的第一焊接步骤，以及将已结合的第三和第二层与所述第一层结合在一起的第二焊接步骤。
此外，根据实施例，本发明优选被设置为由其孔隙半径等于或大于第二层和第三层孔隙半径的材料形成第一层，并且由其孔隙半径等于或大于第三层孔隙半径的材料形成第二层。这有助于提供在流体吸收性、再湿性和干燥度方面与现有技术比较具有更好性能的吸收性物品。
附图说明
现在将参照优选实施例和附图对本发明进行描述，其中：
图1为根据本发明原理用于制造吸收性本体的设备的示意图；
图2a为示出根据本发明的第一结合步骤的示意性透视图；
图2b为示出根据本发明的第二结合步骤的示意性透视图；
图3为示出吸收性本体孔隙半径的原理的示意图；
图4为示出根据本发明原理形成的层叠结构的孔隙梯度的原理的示意图；
图5为示出层叠结构的多种孔隙半径的原理的示意图；
图6为进一步解释涉及焊接根据本发明层叠结构的方法的原理的示意图；以及
图7为示出本发明原理的曲线图。
具体实施方式
现在将参照本发明的实施例描述本发明的原理。更精确地，本发明适用于与例如形为薄卫生巾的吸收性本体有关。但是，本发明并不仅限于这种吸收性本体，原则上还可用于制造尿布、卫生护垫、失禁垫、培训裤和类似用品。
本发明意图在制造这种吸收性物品期间使用。更精确地，本发明通常用于将两个或更多个材料层--通常为纤维层--接合在一起形成最终吸收性物品的一部分。
图1示出用于制造由多个材料层构成的这种层叠品的设备1。该设备包括第一辊2和带有超声变幅器4的超声波焊接装置3。该变幅器4位于与辊2相对距离较小的预定位置处，从而限定了供特定材料层穿过以被供给的间隙5。根据适宜的实施例，本发明被设置为将第一层6、第二层7和第三层8粘合在一起。此外，根据一实施例，第一层6为液体可渗透顶层，第二层7为吸收性本体并且第三层8为液体不可渗透背层。但是，如下所述，本发明并不仅限于这样的构型，而是能根据所附权利要求而改变。
如图1所示，第二材料层7沿第二辊9被适当地引导。根据本实施例，本发明被设置为以一系列工艺步骤运行。这些工艺步骤的第一步是将第三层8和第二层7粘合在一起。在该步骤之后，将由第三层8和第二层7形成的层叠品与第一层6接合在一起。
根据之前已知的原理，第一辊2形成有形为其外表面上特定表面结构的图案(未示出)。该图案的目的是在超声波变幅器4的运行期间有助于将第三层8和第二层7粘合在一起。基于与最终层叠品的所需款式和外观相关的要求来限定例如图案的款式、尺寸和深度这些特性。第一辊2上的图案适宜地包括凹陷部分和凸起部分，其中凸起部分构成当第三层8和第二层7彼此固定时的粘合点即结合位点。图案的深度优选为约0.3-2mm量级。
同样，之前已知超声波焊接装置3可使用的方式，为此将不再详述。但是要注意，超声波焊接装置通常可用于焊接、切割、穿孔或其它类型的材料处理。在本发明的上下文中，假定所述讨论的处理是超声波焊接，目的是将吸收性物品的两个或更多个材料层结合在一起从而提高吸收性物品的排水和扩散性能。本发明特别设置为使用超声波焊接从而改变或适配形成物品一部分的层6、7、8的孔隙结构。特别地，本发明设置为通常将整个吸收性物品焊接在一起从而改变孔隙结构。
图1所示的第二和第三材料层7、8通过间隙5被供给从而通过上述设在第一辊2上的给定结合图案被结合在一起。根据对最终用品的视觉外观即款式相关的要求以及根据对两个材料层7、8之间结合强度的相关要求和对最终用品的其它要求来选择结合图案。
当第二和第三材料层7、8已经结合在一起形成层叠品时，它们朝第三辊10和具有超声波变幅器12的第二超声波焊接装置11被供给。第二间隙13以与第一间隙5对应的方式被限定在第三辊10与第二超声波变幅器11之间。第二和第三材料层7、8被层叠至也通过第二间隙13被供给的第一材料层6。为此，第一材料层6沿第四辊14被适宜地引导。材料层6、7、8沿图1箭头所示的方向被供给。
在第二超声波焊接装置11处的结合操作以一种与第一超声波焊接装置3提供的第一结合图案类似或不类似的另一种结合图案进行。已就第一超声波焊接装置3描述过的款式和可能尺寸的相同原理也适用于第二超声波焊接装置11。
用于结合三个材料层6、7、8的两个上述焊接步骤被设置为赋予最终吸收性物品以所需款式和特定强度。应当注意，物品的强度首先取决于结构由于焊接工艺而变得更稳定这个事实，再者取决于焊接工艺导致相对膨松(bulky)的结构从而提供更好舒适度这一事实。其它特性如捕获流体程度、干燥性和流体扩散性至少部分地由上述两个焊接步骤来确定。
包括三个材料层6、7、8的组合层叠品适用于制造吸收性物品。仅作为实施例，假定第一层6为液体可渗透顶层，适宜地为基于人造或天然纤维的无纺材料，被设置为在其使用中最接近最终物品的穿戴者身体。根据该实施例，第一层6适宜地由人造纤维如聚乙烯、聚丙烯、聚酯、尼龙或类似物构成的无纺材料制造而成。也可使用其它纤维如粘合纤维、共聚物纤维、裂散纤维、纳米纤维等。此外，不同类型的纤维混合物也可用于该目的。可选地，第一层6可由其它材料如热塑性膜或聚酯膜，或层叠品或不同层叠品的组合而制成。根据预定图案，它也可为穿孔或不穿孔的。
对于第一材料层6，还要注意本发明被适宜地实施为能使第一材料层6是层叠品内的不同层6、7、8之中孔隙最大的。最大的孔隙相对更容易排水，意味着第一材料层6的孔隙结构内持有的液体相对容易排入相邻材料层即第二材料层7内。该特征基于这样的理解：相对较大的孔隙易于排空。因此本发明的目的在于通常立即地排空第一材料孔隙中的流体。
换句话说，优选地第一材料层6被选择为能使其具有比其余层7、8更大的孔隙从而提供有效的流体排出。此外，第一层6孔隙数量(magnitude)的局限性和尺寸主要与更下面的层7、8相关。下面将参照图3-5详述这些原理。
此外，优选第一层6被设计为具有某些选定尺寸，即，其尺寸被选定为使其最大厚度优选为5mm量级并且其最大单位织物重量优选约100g/m2，最优选50g/m2。此外，第一层6本身可为具有不同类型纤维结构的层叠品的形式。但是，总的单位织物重量应当优选不超过100g/m2。
此外，也根据图1所示实施例，第二层7可为吸收性结构或层或吸收芯的形式，适宜地包括纤维材料，被设计为具有适宜的流体捕获度、扩散性和吸收性。为此，第二层7可为多孔、弹性、相对较厚的材料层，例如纤维填料或具有较高流体吸入性和较高流体吸收性的类似类型的材料。
第二层7可包括天然或人造纤维或这些纤维的混合物。此外，第二层7可包括适宜量的超吸收材料。这种配置有助于所完成的吸收性物品具有极高的吸收率。此外，第二层7可为单一材料层或层叠品。在后一种情形下，第二层7可由填料层和吸收芯的层叠品构成。
还要提及的是，第二层7可包括适宜量的热塑性纤维从而使得超声波焊接工艺以适宜方式进行。
此外，根据本发明原理，第二层7优选被设计为具有比第一层6更精细的孔隙结构，即孔隙半径小于第一层6。再者，第二层7的孔隙半径应当大于第三层8的孔隙半径，即第二层7比第三层8(以及任意其它更下面的层)的纤维结构更为粗糙。
最后，根据本实施例，第三层8可为优选液体不可渗透(或至少极其抗渗水)的背层层并且因此被提供来防止流体从最终物品中泄漏出。为此，第三层8适宜地由液体不可渗透材料如薄的密封塑料膜制造而成。例如，由聚乙烯、聚丙烯或聚酯制造的塑料膜可用于该目的。
根据可选实施例，第三材料层8可为与上述背层不同的类型，如又一吸收层。
此外，图2a示出根据本发明适宜实施例用于第三材料层8和第二材料层7的结合工艺的简化透视图。该图示出第二和第三层7、8被引导通过第一超声波焊接装置4并且被结合在一起从而制造了第一结合图案15。例如根据物品的视觉外观、最终物品的强度和流体捕获特性来选择第一结合图案15的实际款式。该结合图案15的实际款式可多变。例如，结合图案15可为正方形或矩形图案，在结合位点之间的距离为1-3cm。优选地，结合图案15的结合位点之间的距离应当不超过约3cm，从而为物品提供有效排水。
图2a还示出根据本发明材料层8、7据此被设置的坐标***。更精确地，材料层8、7延伸的纵向指的被称为x方向。与x方向相横的方向被称为y方向，并且垂直于通常由每个材料层8、7表面限定的平面的方向被称为z方向。
在第三层和第二层8、7已被结合在一起后，它们以类似方式通过第二超声波变幅器11进一步被结合于第一层6。这在图2b中示意性地示出。以这种方式限定出也包括多个结合位点18的第二结合图案17。根据本实施例，第一结合图案15和第二结合图案17彼此不同，但它们也可以具有相似形式。
将层6、7、8焊接在一起的顺序因此由图2a和2b示出。本发明的重要特点在于以特定顺序进行焊接，即首先是第三材料层8(适宜地为背层)和第二材料层7(适宜地为吸收层)。当这两层7、8已经被结合后，第一层6(适宜地为顶层)也通过结合而适宜地被添加于其它层。
因此，为提供根据本发明原理的层叠品，由此优选通过焊接第二和第三层7、8(即在吸收性物品的使用中距离身体最远的那些层)来开始该工艺。原因在于(即如果从最上面的第一层6开始)存在孔隙过小并且因此第一层6变得太密集而不可渗透液体的危险。这就与本发明的目的相悖。这样当焊接于其余层时就不可能建立更精细的纤维结构(即具有更小孔隙)。在这种情形下，不可能有效排水。
另一个重要原理在于，适于在形成最终用品的所有材料层6、7、8(即包括在这种情形下为吸收层的第二层7)之间进行焊接。
为进一步解释本发明的原理和特点，现在要描述一些基本概念。首先，上述提到的术语“孔隙半径”现在将参照图3进行描述，图3示出带有由纤维材料形成的网丝20或基体的吸收层19的横截面。纤维网丝20限定了多个孔，每个孔具有特定尺寸和体积。例如，某个孔在图3中通过附图标记21来图示。对于该孔21(以及网丝20内的任何孔)来说，可测定其“孔隙半径”的尺寸。由于纤维网丝20的不规则形状，这些孔显然不是完美的圆形。取而代之的是，孔的“有效”孔隙半径R的大小可通过拉普拉斯公式来得到。这是已知的所以此处不再详述。只提到有效孔隙半径R是根据下面关系式的近似值：
R＝2YLcosθa，r/Δp
其中γL是液体表面张力，θa，r是液体相对于结构的前进或后退接触角并且Δp是横跨限定出朝向空气的液体表面的弯月面的压差。
本发明的原理将参照图4进一步描述，图4示出由对应于本发明的三个材料层6、7、8的三个不同纤维层构成的层叠结构(也称为层叠品)22。在各层6、7、8中的三个不同孔23、24、25的示例在图中示出。如上所示，本发明被设置为使得第一层6由相应孔23的孔隙半径为R1的材料形成，该孔隙半径R1等于或大于第二层7的相应孔24的孔隙半径R2和第三层8的相应孔25的孔隙半径R3。此外，形成第二层7的材料具有的孔隙半径R2等于或大于第三层8的孔隙半径R3。由于从第一材料层6朝向第三材料层8的孔隙半径逐渐减小，这就意味着层叠品具有沿z方向(参见图2a)变化的孔隙梯度。
例如，要提到的是，其中各材料层分别限定了特定大小孔隙半径以使R1＜R2＞R3的这样一种层叠品(图中未示出)不会以本发明限定的方式起作用。特别地，这种方案不能提供预期的排水效果，因为流体不能以有效方式从顶层朝中间层抽吸。
根据本实施例，层叠品结果被制造成使其具有在贯穿最终层叠品方向(Z方向)上的孔隙梯度，即最终物品顶侧具有相对“松散”和“开放”的孔隙结构，并且物品的后侧具有更“密集”和“封闭”的孔隙结构。
作为其中第一材料层6具有与第二材料层7和第三材料层8尺寸不同的孔的上述实施例的可选方案，应当注意，本发明也可被实施成使得所有材料层6、7、8包括基本相同大小的孔。所述第一种情形是基于这样的原理：根据本发明使用具有不同孔隙大小的层6、7、8但在上述两个焊接步骤中使用基本相同的焊接图案来得到多种孔隙梯度。另一方面，第二种情形是基于这样的原理：通过使用两种不同的焊接图案但使用具有基本相同孔隙大小的材料层来得到多种孔隙梯度。这两种可选方案都可能在本发明的范围内实现。
此外，图5为根据本发明又一实施例的层叠品22’的示意性截面图。层叠品22’包括分别具有特定孔隙半径的三个材料层6’、7’、8’，其中至少第一层6’的孔隙半径沿x和y方向变化。这就意味着第一层6’由沿纵向即x方向具有不同纤维结构的材料制成。此外，这些结构均具有不同的孔隙半径。这在图5中示出，其中示出第一层6’包括具有不同孔隙半径的三个不同孔26、27、28。
焊接操作导致图5中材料层6’、7’、8’的孔在结合位点16附近更小且更密集。此外，要注意，也是由于焊接，围绕该结合位点16得到x和y方向上的孔隙梯度。
由此，本发明优选被设置为层叠结构在z方向以及x和Y方向上都具有孔隙梯度。
实际超声波焊接工艺基于这样的原理：第二和第三层7、8通过包括多个结合位点16的第一结合图案15(参见图2a)彼此结合，通过挤压这些材料层7、8(当通过间隙5时)和借助超声波变幅器4提供适宜量的能量来形成这些结合位点。这就导致材料层7、8的材料在结合位点16限定的位置处***和融化从而结合在一起。
用于每个结合步骤中的结合图案15、17被选择为实现更好的排水和扩散性能。根据本发明，特别地通过将结合图案15、17选择为能使最终的吸收性物品具有多种孔隙半径来得到最终物品更好的排水和扩散性能以及材料层之间更好的接触。这样物品还具有更干爽的表面和更好舒适度的优点。
这就意味着，根据本发明，孔隙半径可被控制为使例如第一结合图案15的结合位点16被选择为具有第一预定孔隙半径并且第二结合图案17的结合位点18被选择为具有与第一结合图案15孔隙半径不同的第二预定孔隙半径。
吸收性物品的孔隙梯度影响了将被输入下层的液体的导入。根据本实施例，优选地，通过将不同层的孔布置成对于每层或每个焊接操作步骤来说孔越来越“密集”，从而控制孔隙梯度。本发明基于这样的原理：所有材料层6、7、8都使用超声波焊接来进行结合，其中结合图案15、17被选择为对于每个结合操作都优化孔隙梯度。
图6为进一步示出根据本发明用于焊接层叠结构22的原理的示意性截面图。该图基本对应于图4，但特别地示出三个材料层6、7、8都配备有特定的焊接图案。更精确地，第二材料层7和第三材料层8通过如图6所示为多个结合位点16’的第一焊接图案被结合。此外，当第二和第三层7、8被结合并形成层叠品时，第一材料层6通过图6所示为多个其它结合位点16”的第二焊图案被结合于该层叠品。
图6所示焊接操作的结果就是完成的焊接图案是由连接第二和第三层7、8的结合位点16’以及结合所有层6、7、8的其它结合位点16”导致的。这就意味着在第二和第三层7、8之间将有比第一与第二层6、7之间更多的焊接位点。这样，可通过焊接操作来控制层叠结构22的孔隙梯度。
在本发明的上下文中，优化孔隙梯度意味着更好地影响最终物品的排水、扩散性和干燥度。
例如，本发明可以这种方式实施：其中材料朝物品后部(底部)比朝表面部分开放的更多，从而得到具有极高程度流体扩散性的物品并且流体可从物品表面迅速被运走。此处，应当注意，在材料层6、7、8之间实现紧密接触是很重要的。使用上述超声波焊接步骤使之成为可能。
通过上述焊接步骤形成略微“膨松”的结构这一事实，本发明还提供了一种改进的更柔软的材料结构。这意味着上层形成有“顶坝”或“***”，其趋于在使用者身体与上层表面之间形成增大的容积。由此，在使用者与物品之间形成一柱或一条气流，这有助于流体的输入效率。还有助于提高舒适度，因为流体更迅速地被吸入用品中并且可避免在使用者身体与吸收性物品之间形成液体薄膜或薄层。
本发明基于这样的原理：使用不同的结合图案将提供具有多种孔隙半径的用品。图7为示出根据该原理的本发明目的和功能的两条曲线的示意图。
被示为连续实线的第一曲线29教导了用于吸收性物品的常规层叠结构的孔隙体积分布(即不是以本发明限定的方式焊接的层叠结构)是如何随孔隙半径而变的。以虚线示出的第二曲线30教导了根据本发明被焊接和别样设置的层叠结构的相应情形。
根据这些曲线，应当注意，根据本发明的层叠品具有比之前已知材料更低的孔隙体积分布(对于给定的孔隙半径)。这意味着根据本发明的材料比现有物品具有更高程度的排水性，这是非常有利的，因为让使用者感觉更干爽。
此外，第一曲线29教导发明提供的层叠品的孔隙体积分布通常独立于孔隙半径。与此相反，如第二曲线30所示，根据本发明的层叠结构具有的孔隙体积分布极大地取决于孔隙半径。特别地，第二曲线30具有对应于预定大小孔隙半径的“峰值”，意味着该孔隙半径对应于被收集在物品表面部分内相对较大的流体量。
根据本发明，通过将第二曲线30的“峰值”朝图中的左边移动，可得到更好排水的物品。更精确地，本发明被设置为对于每个正进行的焊接步骤都将曲线30朝左移动。由于孔隙半径R的减小在孔内形成的压力更高的事实可解释这一现象。这意味着更多流体将从结构中释放出来。通过图7的箭头示意性示出第二曲线30朝左的“位移”。
此外，由于最接近使用者身体的第一层6具有的孔隙半径等于或大于第二层7和第三层8的孔隙半径，并且第二层7的孔隙半径等于或大于第三层8的孔隙半径，通过本发明可实现更好的排水。
本发明不局限于上述实施例而是在所附权利要求的范围内变化。例如，本发明不限于吸收性物品的任何特定类型，而是可用于制造尿布、卫生护垫、失禁垫、培训裤和通常其它任何类型的吸收性物品。此外，可使用许多类型的材料和材料组合来实施本发明。
本发明的基本理念已经参照具有三个不同层的实施例进行了描述。但是，可选地通过不同数目的层和不同数目的超声波焊接步骤以及不同于上述类型的不同类型层来实施本发明。例如，本发明可实施于具有两个无纺层和两个吸收芯的结构中。可选地，本发明还可实施于具有一个无纺层、两个吸水芯和一个背层的结构中。通过，本发明可以这种方式实施：其中多个层形成层叠结构，并且其中使用的焊接图案优选被选择为使通常整个层叠结构具有多种孔隙半径。
此外，不同层的超声波焊接可在同一步骤或多个连续步骤中完成。

Claims (12)

1.一种用于制造层叠结构(22)的方法，该层叠结构用于吸收性物品如尿布、卫生巾、卫生护垫、失禁垫等且由多个材料层(6，7，8)来限定，包括至少液体可渗透的第一层(6)、构成吸收芯(7)的第二层(7)、以及第三层(8)，所述各层(6，7，8)都由具有特定孔隙半径(R1，R2，R3)的材料形成，所述方法包括：
通过至少两个超声波焊接步骤(4；12)将所述材料层(6，7，8)结合在一起；以及
为每个所述焊接步骤都提供超声波焊接图案(15；17)，每个所述焊接图案(15；17)由多个结合位点(16；18)所限定；
其特征在于，包括：
提供用于形成通常整个吸收性物品的所述焊接步骤(4；11)；以及
以使得至少整个层叠结构(22)具有多种孔隙半径的方式来选择所述焊接图案(15；17)。
2.如权利要求1所述的方法，其特征在于，所述焊接步骤(4；11)以如下的顺序包括至少以下步骤：
所述第三层(8)和所述第二层(7)结合在一起的第一焊接步骤；以及
已结合的第三和第二层(8，7)与所述第一层(6)结合在一起的第二焊接步骤。
3.如权利要求1所述的方法，其特征在于，使用由其孔隙半径等于或大于第二层(7)和第三层(8)孔隙半径的材料形成的第一层(6)并且还使用由其孔隙半径等于或大于第三层(8)孔隙半径的材料形成的第二层(7)来进行所述焊接步骤。
4.如任意一项前述权利要求所述的方法，其特征在于，所述第三层(8)是液体不可渗透的背层。
5.一种用于制造层叠结构(22)的设备(1)，该层叠结构用于吸收性物品如尿布、卫生巾、卫生护垫、失禁垫等且由多个材料层(6，7，8)来限定，包括至少液体可渗透的第一层(6)、构成吸收芯(7)的第二层(7)、以及第三层(8)，所述各层(6，7，8)都由具有特定孔隙半径(R1，R2，R3)的材料形成，所述设备包括：
用于将所述材料层(6，7，8)结合在一起的至少两个超声波焊接装置(3，4；11，12)；
每个所述超声波焊接装置(3，4；11，12)被设置为提供由多个结合位点(16；18)限定的超声波焊接图案(15；17)；
其特征在于，所述超声波焊接装置(3，4；11，12)被设置为提供用于形成整个吸收性物品的所述焊接步骤(4；11)，其中所述焊接图案(15；17)以使得至少整个层叠结构(22)具有多种孔隙半径的方式被选择。
6.一种用于吸收性物品如尿布、卫生巾、卫生护垫、失禁垫等且由多个材料层(6，7，8)限定的层叠结构(22)，包括至少液体可渗透的第一层(6)、构成吸收芯(7)的第二层(7)、以及第三层(8)，所述各层(6，7，8)都由具有特定孔隙半径(R1，R2，R3)的材料形成，通过至少两个超声波焊接步骤(4；12)且为每个所述焊接步骤提供超声波焊接图案(15；17)以将所述材料层(6，7，8)结合在一起来形成所述层叠结构(22)，每个所述焊接图案(15；17)由多个结合位点(16；18)来限定；其特征在于，通过其中通常形成整个吸收性物品的所述焊接步骤(4；11)来形成层叠结构(22)；并且以使得至少整个层叠结构(22)具有多种孔隙半径的方式来选择所述焊接图案(15；17)。
7.如权利要求6所述的层叠结构(22)，其特征在于，所述第三层(8)为液体可不渗透的背层。
8.如权利要求6或7所述的层叠结构(22)，其特征在于，通过以如下顺序且包括至少以下步骤的所述焊接步骤(4；11)形成该层结构：所述第三层(8)和所述第二层(7)结合在一起的第一焊接步骤；以及已结合的第三和第二层(8，7)与所述第一层(6)结合在一起的第二焊接步骤。
9.如权利要求6-8任意一项所述的层叠结构(22)，其特征在于，使用由其孔隙半径等于或大于第二层(7)和第三层(8)孔隙半径的材料形成的第一层(6)并且还使用由其孔隙半径等于或大于第三层(8)孔隙半径的材料形成的第二层(7)来进行所述焊接步骤。
10.如权利要求6所述的层叠结构(22)，其特征在于，它包括两个无纺层和两个吸收芯。
11.如权利要求6所述的层叠结构(22)，其特征在于，它包括一个无纺层、两个吸收芯和一个背层。
12.包括根据权利要求6-9中任一项所述层叠结构(22)的吸收性物品。
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CN106393699A (zh) * 2015-09-10 2017-02-15 杭州珂瑞特机械制造有限公司 拉拉裤在线超声波焊接生产设备及焊接方法
CN106859859A (zh) * 2015-12-14 2017-06-20 叶正瑜 一种卫生用品吸水芯体及其制造方法、制造设备
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CN111479541A (zh) * 2017-12-21 2020-07-31 易希提卫生与保健公司 具有包括焊接点的密封装置的吸收性物品及制造该吸收性物品的方法
US10966882B2 (en) 2017-12-21 2021-04-06 Essity Hygiene And Health Aktiebolag Absorbent article and method for manufacturing absorbent article
CN111479541B (zh) * 2017-12-21 2021-09-28 易希提卫生与保健公司 具有包括焊接点的密封装置的吸收性物品
US11229561B2 (en) 2017-12-21 2022-01-25 Essity Hygiene And Health Aktiebolag Absorbent article and method for manufacturing an absorbent article
US11612525B2 (en) 2017-12-21 2023-03-28 Essity Hygiene And Health Aktiebolag Absorbent article and method for manufacturing an absorbent article
US11793683B2 (en) 2017-12-21 2023-10-24 Essity Hygiene And Health Aktiebolag Absorbent article and method for manufacturing an absorbent article
US11833015B2 (en) 2017-12-21 2023-12-05 Essity Hygiene And Health Aktiebolag Absorbent article and method for manufacturing an absorbent article

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US8669412B2 (en) 2014-03-11
PL2288319T3 (pl) 2016-06-30
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JP2011517989A (ja) 2011-06-23
BRPI0822518B1 (pt) 2019-06-04
MX2010010862A (es) 2010-11-05
BRPI0822518B8 (pt) 2021-06-22
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JP5241914B2 (ja) 2013-07-17
EP2288319A4 (en) 2013-08-07

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