CN104135982B - 用于粘结基底的设备和方法 - Google Patents

用于粘结基底的设备和方法 Download PDF

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Publication number
CN104135982B
CN104135982B CN201380010366.0A CN201380010366A CN104135982B CN 104135982 B CN104135982 B CN 104135982B CN 201380010366 A CN201380010366 A CN 201380010366A CN 104135982 B CN104135982 B CN 104135982B
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Prior art keywords
substrate
rotating cylinder
fluid
press members
described rotating
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CN201380010366.0A
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CN104135982A (zh
Inventor
U·施奈德
D·C·欧德维
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Procter and Gamble Ltd
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Procter and Gamble Ltd
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Publication of CN104135982A publication Critical patent/CN104135982A/zh
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    • A61F13/15585—Apparatus or processes for manufacturing of babies' napkins, e.g. diapers
    • A—HUMAN NECESSITIES
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Abstract

一种接合纤维网部分的方法包括将纤维网部分推进到旋转的转筒上，使得当纤维网部分围绕转筒包裹时，纤维网部分在重叠区域重叠。这些纤维网部分各自具有熔融温度。将流体加热至足以至少部分地熔融纤维网部分的温度。流体喷嘴从转筒中的孔回缩，并且受热流体的射流在重叠区域从流体喷嘴被引导到纤维网部分上。受热流体渗透并至少部分地熔融纤维网部分。使用受热流体来至少部分地熔融纤维网部分。压制构件移位穿过转筒中的孔以在压力构件和砧辊之间压缩纤维网部分，从而在重叠区域将纤维网部分接合在一起。

Description

用于粘结基底的设备和方法
技术领域
本公开涉及用于制造吸收制品的方法，更具体地，本公开涉及用于在吸收制品的制造期间将组件粘结在一起的设备和方法。
背景技术
沿着组装线，可通过将组件添加到推进的连续材料纤维网上和/或以其它方式修改推进的连续材料纤维网来组装各种类型的制品，诸如例如尿布和其它吸收制品。例如，在一些方法中，推进的材料纤维网与其它推进的材料纤维网相结合。在其它例子中，从推进的材料纤维网产生的单独的组件与推进的材料纤维网相组合，然后所述推进的材料纤维网继而与其它推进的材料纤维网相组合。在一些情况下，由推进的一个或多个纤维网产生的单独的组件与由其他推进的一个或多个纤维网形成的其他单独的组件组合。用来制造尿布的材料纤维网和组件部件可包括：底片、顶片、腿箍、腰带、吸收芯组件、前耳片和/或后耳片、扣紧组件、以及各种类型的弹性纤维网和组件诸如腿弹性部件、阻隔腿箍弹性部件、拉伸侧片和腰弹性部件。一旦装配好了所期望的组件部件，就使推进的纤维网和组件部件经受最终刀切以将该纤维网分隔成离散的尿布或其它吸收制品。
在一些转换加工构型中，彼此间隔开的离散的基础结构在纵向上被推进并且被布置成具有平行于横向的纵向轴线。然后将离散的基础结构的相对的腰区与在纵向上推进的连续长度的可弹性延伸的前带纤维网和后带纤维网连接。虽然是与基础结构连接，但前带纤维网和后带纤维网沿纵向以完全拉伸状态保持着，从而形成连续长度的吸收制品。然后可在横向上折叠所述连续长度的吸收制品。在折叠过程期间，在一些转换加工构型中，前带纤维网和后带纤维网中的一者被折叠成与相对的带成面对关系。然后前带和后带可被粘结在一起以在尿布上产生侧缝。
因此，有益的是提供用于更精密地控制用来形成侧缝的粘结件的位置和强度的方法和设备。
发明内容
本公开的方面涉及用于制造吸收制品的设备和方法，更具体地，涉及用于在一次性吸收制品的制造期间接缝纤维网的方法。本文所公开的制造方法的具体实施例提供用于形成各种类型的尿布构型中的侧缝。虽然本公开主要涉及的是在尿布裤中形成侧缝，但应理解，本文所公开的方法和设备也可应用于在尿布以及其它类型的吸收制品上使用的其它接缝。
在一个实施例中，用于形成接缝的方法包括以下步骤：围绕旋转轴线旋转转筒，该转筒包括流体喷嘴和压制构件；旋转邻近转筒的砧辊；在纵向上将第一基底推进到转筒上，第一基底具有内表面和外表面，其中第一基底的外表面邻近转筒；在纵向上推进第二基底，其中第一基底位于第二基底和转筒之间；围绕转筒的一部分包裹第一基底和第二基底；将流体加热至足以至少部分地熔融基底的温度；从转筒径向向外移动流体喷嘴；将受热流体的射流引导到第一基底和第二基底上；部分地熔融第一基底和第二基底；将流体喷嘴径向向内回缩到转筒中；从转筒径向向外移位压制构件；以及在压制构件和砧辊之间压缩第一基底和第二基底。
在另一个实施例中，用于将基底粘结在一起的设备包括用于连续地推进第一基底和第二基底的转筒。转筒包括转筒外圆周表面和转筒外圆周表面中的转筒孔。转筒适于围绕旋转轴线旋转。该设备包括可移动地连接至转筒的流体喷嘴，所述流体喷嘴位于转筒孔的径向内部，并且适于朝第一基底和第二基底径向向外引导流体穿过转筒孔。该设备也包括位于邻近转筒处的砧辊，该砧辊适于围绕旋转轴线旋转。该设备还包括可移动地连接至转筒的压制构件，所述压制构件位于转筒孔的径向内部，并且适于延伸穿过转筒孔以在砧辊之间压缩第一基底和第二基底从而形成粘结件。
附图说明
图1为尿布裤的透视图。
图2A为图1所示尿布裤在部分切除之后的平面图。
图2B为尿布裤的第二实施例在部分切除之后的平面图。
图3A为沿线3A-3A截取的图2A和2B的尿布裤的剖面图。
图3B为沿线3B-3B截取的图2A和2B的尿布裤的剖面图。
图4为适于制造预扣紧的裤型尿布的转换加工设备的示意性侧视图。
图5A为沿线A-A截取的出自图4的连续长度的基础结构组件的视图。
图5B1为沿线B1-B1截取的出自图4的离散的基础结构的视图。
图5B2为沿线B2-B2截取的出自图4的离散的基础结构的视图。
图5C为沿线C-C截取的出自图4的连续长度的推进的前侧片材料和后侧片材料的视图。
图5D为沿线D-D截取的沿纵向MD彼此间隔开的且由出自图4的前侧片材料和后侧片材料彼此连接的多个离散的基础结构的视图。
图5E为沿线E-E截取的折叠的多个离散的基础结构的视图，所述基础结构带有呈面对关系的出自图4的前侧片材料和后侧片材料。
图5F为沿线F-F截取在纵向MD上推进的出自图4的两个离散的吸收制品的视图。
图6A为适于接缝预扣紧的裤型尿布的粘结机设备的示意性侧视图。
图6A1为图6A的粘结机设备的详细的示意性侧视图。
图6B为图6A的接缝机工位的正视图。
图6B1为图6B的接缝机工位的详细正视图。
图6C为适于接缝预扣紧的尿布的粘结机设备的另一个实施例的示意性侧视图。
图6D为适于接缝预扣紧的尿布的粘结机设备的另一个实施例的示意性侧视图。
图7为接缝设备的一个实施例的详细分解图。
图8为接缝工位的一个实施例的正视图。
图9为处于第一构型的接缝工位的一个实施例的透视图。
图10为处于第二构型的接缝工位的一个实施例的透视图。
图11为粘结机设备的示意图，示出了围绕转筒的接缝工位的所述各种构型。
图12为处于第一构型的接缝工位的示意性侧视图。
图13为从第一构型移位至第二构型的接缝工位的示意性侧视图。
图14为处于第二构型的接缝工位的示意性侧视图。
图15为从第二构型复位至第一构型的接缝工位的示意性侧视图。
图16为接缝工位的一个实施例的正视图。
具体实施方式
以下术语的解释可适用于理解本公开：
本文所用的“吸收制品”是指主要功能为吸收和保留污垢和***物的消费品。“尿布”在本文中用来指一般由婴儿和失禁患者围绕下体穿着的吸收制品。术语“一次性的”在本文中用来描述通常不打算洗涤或换句话讲复原或作为吸收制品再使用的吸收制品(例如，它们旨在在单次使用后丢弃，并且也可被构造成可回收利用、堆肥处理或换句话讲以其它与环境相容的方式进行处理)。
“弹性的”、“弹性体”或“弹性体的”是指材料表现出弹性性能，它们包括如下任何材料，在向其松弛的初始长度施加力时所述材料能够拉伸或伸长至比其初始长度超出10％的伸长长度，并且在释放所施加的力时将基本上回复至大约其初始长度。
如本文所用，术语“接合”包括其中通过将元件直接附连到另一元件而使该元件直接固定到另一元件上的构型，以及其中通过将元件附连到一个或多个中间构件，中间构件又被附连到另一元件而使该元件间接固定到另一元件上的构型。
“纵向”是指当制品处于平坦未收缩状态时从吸收制品的腰部边缘到纵向相对的腰部边缘，或者在双折的制品中从腰部边缘到裆的底部(即折叠线)基本上垂直延伸的方向。在纵向的45度以内的方向被认为是“纵向”。“侧向”是指由制品的纵向延伸的侧边向侧向相对纵向延伸的侧边穿行且大体与纵向成直角的方向。在侧向的45度以内的方向被认为是“侧向”。
“径向”是指从转筒中心朝转筒外圆周表面延伸的方向。
术语“基底”在本文中用来描述如下材料，所述材料主要为二维的(即在XY平面中)，并且其厚度(在Z方向上)与其长度(在X方向上)和宽度(在Y方向上)相比相对较小(即1/10或更小)。基底的非限制性实例包括纤维网、一层或多层或纤维材料、非织造织物、膜和薄片诸如聚合物膜或金属薄片。这些材料可单独使用或可包括层压在一起的两个或更多个层。因此，纤维网为基底。
术语“非织造织物”在本文中是指采用诸如纺粘法、熔喷法、梳理法等方法由连续(长)丝(纤维)和/或不连续(短)丝(纤维)制成的材料。非织造材料不具有纺织长丝或编织长丝模式。
术语“纵向”(MD)在本文中用来指加工过程中材料流的方向。此外，材料的相对放置和移动可被描述为在纵向上从工艺上游至工艺下游的流动过程。
术语“横向”(CD)在本文中用来指大致垂直于纵向的方向。
术语“裤”(也称为“训练裤”、“预闭合尿布”、“尿布裤”、“裤型尿布”、和“套穿尿布”)在本文中是指经设计用于婴儿或成人穿着者的具有连续周边腰部开口和连续周边腿部开口的一次性吸收制品。在制品被应用到穿着者之前，裤可用连续的或闭合的腰部开口和至少一个连续的闭合的腿部开口来构造。裤可通过多种技术预形成，所述技术包括但不限于使用任何可重复扣紧的闭合构件和/或永久性闭合构件(例如缝合、热粘结、压力焊接、粘合剂、胶粘剂粘结、机械扣件等)将制品的部分接合在一起。裤可沿制品周围在腰区中的任何位置预形成(例如，侧边扣紧的或接缝的、前腰扣紧的或接缝的，后腰扣紧的或接缝的)。
“预扣紧的”在本文中是指以如下构型制造并提供给消费者的裤型尿布，其中在被应用到穿着者之前，前腰区和后腰区是扣紧的或在包装时是彼此连接的。因此，裤型尿布可具有被设计成用于婴儿或成人穿着者的连续周边腰部开口和连续周边腿部开口。如下文所更详述，尿布裤可通过各种技术来预形成，包括但不限于使用可重复扣紧的和/或永久性闭合构件(例如，接缝、热粘结、压力焊接、粘合剂、胶粘剂粘结、机械扣件等)将尿布的部分接合在一起。此外，裤型尿布还可在沿腰区周围的任何位置预形成(例如，侧边扣紧的或连接的、前腰扣紧的或连接的、后腰扣紧的或连接的)。
本公开涉及用于将基底粘结在一起的方法和设备。如下所更详述，粘结设备可包括转筒和邻近转筒的砧辊。砧辊和转筒可各自包括外圆周表面。转筒也可包括外圆周表面中的孔和位于转筒的外圆周表面的径向内侧的一个或多个接缝工位。如下所更详述，接缝工位可包括可操作地与压制构件的流体喷嘴连接。在粘结操作期间，使转筒围绕旋转轴线旋转，并且第一基底在纵向MD上推进到转筒的外圆周表面上。另外在纵向MD上推进第二基底，其中第一基底位于第二基底和转筒之间。将流体加热至足以至少部分地熔融基底的温度。随着转筒的旋转，流体喷嘴径向向外朝转筒的外圆周表面中的孔移动。流体喷嘴引导受热流体的射流穿过所述孔并到达第一基底和第二基底的重叠区域上，其部分地熔融重叠区域。随着转筒继续旋转，流体喷嘴从所述孔径向向内回缩，并且压制构件径向向外移动穿过所述孔。然后在压制构件和砧辊之间压缩所述部分地熔融的重叠区域，从而在第一基底和第二基底之间产生离散的粘接区或接缝。转筒继续旋转，并且压制构件从所述孔径向向内回缩。
如下所述，粘结设备可被构造成部分地熔融并压缩基底，同时当基底在纵向MD上推进时，在转筒上行进以最小化对弱的部分地熔融的基底所造成的变形。流体喷嘴和压制构件之间的可操作的连接部可被构造成在相同的相对位置部分地熔融并压缩基底以便产生离散的粘结部位。在一些构型中，压制构件也可包括弹簧构件以向压制构件和砧辊之间的重叠区域施加预先确定的力。
应当理解，虽然本文的粘结方法和设备可被构造成粘结各种类型的基底，但下文在制造吸收制品的上下文中讨论本文的方法和设备。具体地，在如下的上下文中讨论这些方法和设备：将带基底粘结在一起以形成在生产期间推进的连续长度的吸收制品的侧缝。如下所述，推进的连续长度的吸收制品可包括与连续的第一带基底和连续的第二带基底连接的多个基础结构。连续的第一带基底和第二带基底在沿纵向MD推进期间可沿横向彼此分隔。每个基础结构均可在横向CD上延伸并可包括由中心区分隔的相对的第一端区和第二端区，其中第一端区连接第一带基底并且第二端区连接第二带基底。基础结构也可沿纵向MD彼此间隔开。折叠设备用来围绕折叠轴线沿中心区折叠基础结构，因而使第二带基底和基础结构的第二端区与第一带基底和基础结构的第一端区成面对关系。在一些实施例中，第一带基底、第二带基底、折叠的基础结构在纵向上推进到旋转的转筒诸如上述转筒的外圆周表面上。随着转筒的旋转，流体喷嘴径向向外朝转筒的外圆周表面中的孔移动。流体喷嘴引导受热流体的射流穿过所述孔并到达第一带基底和第二带基底的重叠区域上，其部分地熔融所述重叠区域。随着转筒继续旋转，流体喷嘴从所述孔径向向内回缩，并且压制构件径向向外移动穿过所述孔。然后在压制构件和砧辊之间压缩所述部分地熔融的重叠区域，从而在第一带基底和第二带基底之间产生离散的粘接部位或接缝。转筒继续旋转，并且压制构件从所述孔径向向内回缩，并且将连续长度的第一带基底和第二带基底从转筒推进至刀辊。这些粘结的区由刀辊沿横向切割以产生吸收制品上的第一侧缝和随后在推进的吸收制品上的第二侧缝。
如前文所提及，本文所讨论的方法和设备可用来粘结各种类型的基底构型，它们中的一些可用于制造不同类型的吸收制品。为了帮助为对该方法实施例的后续的讨论提供另外的上下文，下文提供了对呈尿布形式的吸收制品的一般描述，所述尿布包括可根据本文所公开的方法和设备粘结的组件。
图1和2A示出了尿布裤100的一个实例，其可根据本文所公开的设备和方法来装配和折叠。具体地，图1示出了处于预扣紧构型的尿布裤100的透视图，并且图2A示出了尿布裤100的平面图，其带有背离朝观察者取向的穿着者的尿布的部分。图1和2A所示的尿布裤100包括基础结构102和环状弹性带104。如下文所更详述，第一弹性带106和第二弹性带108连接在一起以形成环状弹性带104。
继续参见图2A，基础结构102包括第一腰区116、第二腰区118、以及设置在第一腰区和第二腰区之间的裆区120。第一腰区116可被构造为前腰区，并且第二腰区118可被构造为后腰区。在一些实施例中，前腰区、后腰区、和裆区中每一个的长度可为吸收制品100的长度的1/3。尿布100也可包括前腰区116中的侧向延伸的前腰边缘121和后腰区118.中的纵向相对且侧向延伸的后腰边缘122。为了为本讨论提供参照系，图2A中的尿布100和基础结构102被示出具有纵向轴线124和侧向轴线126。在一些实施例中，纵向轴线124可延伸经过前腰边缘121并经过后腰边缘122。并且侧向轴线126可延伸经过基础结构102的第一纵向或右侧边缘128并经过第二纵向或左侧边缘130的中点。
如图1和2A所示，尿布裤100可包括内面即面向身体表面132、和外面即面向衣服表面134。基础结构102可包括底片136和顶片138。基础结构102也可包括具有吸收芯142的吸收组件140，所述吸收芯设置在顶片138的一部分和底片136之间。如下文所更详述，尿布100也可包括其它特征结构诸如腿弹性部件和/或腿箍以增强围绕穿着者腿部的贴合性。
如图2A所示，基础结构102的周边可由下列限定：第一纵向侧边128、第二纵向侧边130、设置在第一腰区116中的第一侧向延伸的端边144、和设置在第二腰区118中的第二侧向延伸的端边146。侧边128和130均在第一端边144和第二端边146之间纵向延伸。如图2A所示，侧向延伸的端边144和146位于前腰区116中的侧向延伸的前腰边缘121和后腰区118中的侧向延伸的后腰边缘122的纵向内侧。当尿布裤100被穿着在穿着者下体上时，基础结构102的前腰边缘121和后腰边缘122可环绕穿着者腰部的一部分。同时，基础结构侧边128和130可环绕穿着者腿部的至少一部分。并且裆区120一般可定位在穿着者***，其中吸收芯142从前腰区116穿过裆区120延伸至后腰区118。
还应当理解，尿布100的一部分或全部也可被制造成侧向可延展的。这种附加延展性在穿着者运动期间可帮助允许尿布100适形于穿着者的身体。这种附加延展性也可帮助例如允许包括在延伸之前具有特定尺寸的基础结构102的尿布100的使用者延伸尿布100和/或基础结构102的前腰区116、后腰区118、或这两个腰区，从而提供对具有不同身材大小的穿着者的附加身体覆盖率，即，向个体穿着者定制尿布。只要裆区被延伸到与一个腰区或多个腰区相比相对较小的程度，一个腰区或多个腰区的此类延伸即可使吸收制品具有大致沙漏形形状，并且在制品被穿着时可赋予其定制的外观。
如前文所提及，尿布裤100可包括底片136。底片136也可限定基础结构102的外表面134。底片136可为流体(例如，经液、尿液、和/或稀便)不可透过的，并且可由薄的塑料膜制成，虽然也可使用其他柔性的液体不可透过的材料。底片136可防止吸收芯中所吸收和容纳的流出物润湿与尿布100接触的制品，诸如床单、睡衣和内衣。底片136也可包括机织材料或非织造材料、聚合物膜诸如聚乙烯或聚丙烯的热塑性膜、和/或多层的或复合材料，包括膜和非织造材料(例如，具有内膜层和外非织造层)。底片也可包括弹性体膜。一种实例底片140可为具有约0.012mm(0.5mils)至约0.051mm(2.0mils)厚度的聚乙烯薄膜。示例性聚乙烯膜由ClopayCorporation(Cincinnati，Ohio)以名称BR-120和BR-121制造，并且由TredegarFilmProducts(TerreHaute，Ind.)以名称XP-39385制造。底片136也可进行压花和/或表面打毛以提供更像布料的外观。此外，底片136还可允许蒸气从吸收芯中逸出(即底片是能够透气的)，同时仍然防止流出物透过底片136。底片136的尺寸可取决于吸收芯142的尺寸和/或尿布100的特定构型或尺寸。
还如上所述，尿布裤100可包括顶片138。顶片138也可限定基础结构102的内表面132的全部或一部分。顶片138可为柔顺的、感觉柔软的，并且不刺激穿着者的皮肤。其可在一个或两个方向上弹性拉伸。此外，顶片138还可为液体可透过的，允许液体(例如，经液、尿液和/或稀便)穿透其厚度。顶片138可由宽泛范围的材料制成，诸如织造材料和非织造材料；开孔的或液压成形的热塑性膜；开孔的非织造材料、多孔泡沫；网状泡沫；网状热塑性膜；和热塑性稀松布。织造材料和非织造材料可包括天然纤维，诸如木纤维或棉纤维；合成纤维，诸如聚酯纤维、聚丙烯纤维、或聚乙烯纤维；或它们的组合。如果顶片138包括纤维，则纤维可以由纺粘法、梳理法、湿法成网法、熔喷法、水刺法或其它本领域已知的方法加工。
顶片138可选自高蓬松非织造织物顶片、开孔膜顶片和开孔非织造织物顶片。开孔膜顶片可让身体流出物透过但基本上不吸收它们，并且降低了允许流体回流透过并回渗穿着者皮肤的趋势。示例性开孔膜可包括美国专利5,628,097；5,916,661；6,545,197；和6,107,539中所述的那些。
如上文所提及，尿布裤100也可包括接合到基础结构102的吸收组件140。如图2A所示，吸收组件140在前腰区116中可具有侧向延伸的前边缘148，并且在后腰区118中可具有纵向相对且侧向延伸的后边缘150。吸收组件可具有纵向延伸的右侧边缘152并且可具有侧向相对且纵向延伸的左侧边缘154，这两个吸收组件侧边152和154均可在前边缘148和后边缘150之间纵向延伸。吸收组件140可附加包括一个或多个吸收芯142或吸收芯层。吸收芯142可至少部分地设置在顶片138和底片136之间，并且可按与尿布相容的各种尺寸和形状来形成。用作本公开的吸收芯的示例性吸收结构描述于美国专利4,610,678；4,673,402；4,888,231；和4,834,735中。
一些吸收芯实施例可包括包含减小量的纤维素透气毡材料的流体储存芯。例如，此类芯可包括小于约40％，30％，20％，10％，5％，或甚至1％的纤维素透气毡材料。此类芯可主要包括含量为至少约60％，70％，80％，85％，90％，95％，或甚至约100％的吸收胶凝材料，其中芯的剩余部分包括微纤维胶(如果适用的话)。此类芯、微纤维胶、和吸收胶凝材料描述于美国专利5,599,335；5,562,646；5,669,894；和6,790,798以及美国专利公布2004/0158212和2004/0097895中。
如前文所提及，尿布100也可包括弹性化腿箍156。应当理解，腿箍156可为且有时候也称为腿围、侧翼、阻隔箍、弹性箍或衬圈箍。弹性化腿箍156可按各种方式来构造以帮助减少身体流出物在腿部区中的渗漏。实例腿箍156可包括美国专利3,860,003；4,909,803；4,695,278；4,795,454；4,704,115；4,909,803；和美国专利申请12/434,984中所述的那些。
如上文所提及，尿布裤可被制造成具有环状弹性带104并以如下构型提供给消费者，其中在被应用到穿着者身上之前，前腰区116和后腰区118在包装时是彼此连接的。因此，尿布裤可具有诸如图1所示的连续周边腰部开口110和连续周边腿部开口112。
如前文所提及，环状弹性带104由连接第二弹性带108的第一弹性带106限定。如图2A所示，第一弹性带106限定第一和第二相对的端区106a,106b和中心区106c，并且第二弹性带108限定第一和第二相对的端区108a,108b和中心区108c。
第一弹性带的中心区106c与基础结构102的第一腰区116连接，并且第二弹性带108的中心区108c与基础结构102的第二腰区116连接。如图1所示，第一弹性带106的第一端区106a在第一侧缝178处与第二弹性带108的第一端区108a连接，并且第一弹性带106的第二端区106b在第二侧缝180处与第二弹性带108的第二端区108b连接，从而限定环状弹性带104以及腰部开口110和腿部开口112。
如图2A，3A和3B所示，第一弹性带106也限定外侧向边缘107a和内侧向边缘107b，并且第二弹性带108限定外侧向边缘109a和内侧向边缘109b。外侧向边缘107a，107b也可限定前腰边缘120和侧向延伸的后腰边缘122。第一弹性带和第二弹性带也可各自包括外层即面向衣服层162和内层即面向穿着者层164。应当理解，第一弹性带106和第二弹性带108可包括相同的材料和/或可具有相同的结构。在一些实施例中，第一弹性带106和第二弹性带可包括不同的材料和/或可具有不同的结构。还应当理解，第一弹性带106和第二弹性带108可由各种材料构造成。例如，第一带和第二带可由下列材料制成，诸如塑料膜；开孔塑料膜；天然材料的织造或非织造纤维网(例如，木纤维或棉纤维)、合成纤维(例如，聚烯烃纤维、聚酰胺纤维、聚酯纤维、聚乙烯纤维、或聚丙烯纤维)或天然纤维和/或合成纤维的组合；或涂覆的织造纤维网或非织造纤维网。在一些实施例中，第一弹性带和第二弹性带包括合成纤维的非织造纤维网，并且可包括可拉伸的非织造材料。在其它实施例中，第一弹性带和第二弹性带包括内疏水性不可拉伸的非织造材料和外疏水性不可拉伸的非织造材料。
第一弹性带和第二弹性带106，108也可各自包括插置在外层162和内层164之间的带弹性材料。该带弹性材料可包括一个或多个弹性元件诸如沿弹性带的长度延伸的股线、带状物、或片。如图2A，3A和3B所示，带弹性材料可包括多根弹性股线168，它们在本文中可称作外腰弹性部件170和内腰弹性部件172。如图2A所示，弹性股线168在第一弹性带106的第一和第二相对的端区106a，106b之间且在第二弹性带108的第一和第二相对的端区108a，108b之间连续地侧向延伸。在一些实施例中，一些弹性股线168可被构造成具有区域中断部分，诸如例如其中第一弹性带和第二弹性带106，108重叠吸收组件140。在一些实施例中，弹性股线168可按纵向上的恒定间隔设置。在其它实施例中，弹性股线168可按纵向上的不同间隔设置。处于拉伸状态的带弹性材料可插置并接合在未收缩的外层和未收缩的内层之间。当带弹性材料松弛时，带弹性材料回复至未拉伸状态并使外层和内层收缩。带弹性材料可在环状弹性带区域中提供所期望的收缩力变化。
应当理解，可以除如图2A所示方式之外的不同方式来构造基础结构102和弹性带106，108。例如，图2B示出了尿布裤100的平面图，所述尿布裤具有与上文关于图2A所述的相同的组件，不同的是基础结构102的第一侧向延伸的端边144沿第一弹性带106的外侧向边缘107a对齐并与其重合，并且第二侧向延伸的端边146沿第二带108的外侧向边缘109a对齐并与其重合。
如前文所提及，根据本公开的设备和方法可被利用来装配预扣紧的、可重复扣紧的裤型尿布100的各种组件。例如，图4示出了适于制造裤型尿布100的转换加工设备300的示意图。可参照上文所述且图1和2A所示的裤型尿布100的所述各种组件来描述转换加工设备300的操作方法。虽然以下方法是在图1和2A所示尿布100的上下文中提供的，但应当理解，根据本文所公开的方法可制造尿布裤的各种实施例，诸如例如，提交于2004年11月10日的美国专利7,569,039；提交于2004年11月10日的美国专利公布2005/0107764A1；提交于2011年8月30日的美国专利申请13/221,127；和提交于2011年8月30日的美国专利申请13/221,104中所公开的吸收制品，这些专利均以引用方式并入本文。
如下文所详述，图4所示的转换加工设备300用来沿纵向MD推进离散的基础结构102，使得每个基础结构102的侧向轴线平行于纵向，并且其中基础结构102沿纵向彼此间隔开。然后将间隔开的基础结构102的相对的腰区116,118与连续长度的推进的第一弹性带基底406和第二弹性带基底408连接。然后沿侧向轴线折叠基础结构102以使第一弹性带基底406和第二弹性带基底408成面对关系，并且第一弹性带基底和第二弹性带基底沿间歇地沿纵向间隔开的区336连接在一起，其中每个区336均可包括一个或多个离散的粘结部位336a。并且沿区336切割弹性带基底406，408以产生离散的尿布100，诸如图1所示。
如图4和5A所示，在纵向MD上将连续长度的基础结构组件302推进至载体设备308并用刀辊306切割成离散的基础结构102。连续长度的基础结构组件可包括夹置在顶片材料138和底片材料136之间的吸收组件140、腿弹性部件、阻隔腿箍等。基础结构组件的一部分被切除以示出顶片材料138的一部分和吸收组件140。
在用刀辊306切割了离散的吸收基础结构102之后，载体设备308旋转并在纵向MD上以图5B1所示的取向推进离散的基础结构102，其中基础结构102的纵向轴线124大致平行于纵向MD。虽然图5B1所示的基础结构102被示出具有作为前缘的第二侧向延伸的端边146和作为后缘的第一侧向延伸的端边144，但应当理解，在其它实施例中，可按其它取向来推进基础结构102。例如，基础结构可取向成使得第二侧向延伸的端边146成为后缘并且第一侧向延伸的端边144成为前缘。载体设备308也旋转，同时改变推进的基础结构102的取向。载体设备308也可改变基础结构102在纵向MD上推进的速度。应当理解，各种形式的载体设备可与本文的方法一起使用，诸如例如，美国专利7,587,966所公开的载体设备。图5B2示出了基础结构102在纵向上推进时在载体设备308上的取向。更具体地，图5B2示出了如下基础结构102，其中基础结构102的侧向轴线126大致平行于纵向MD，并且其中第二纵向侧边130为前缘且第一纵向侧边128为后缘。
如下文参照图3，5C，5D，5E和5F所述，基础结构102从载体设备308上转移并且与推进的连续长度的带基底406，408结合，所述带基底随后被切割以形成尿布100上的第一弹性带106和第二弹性带108。
参照图3和5C，基础结构102从载体设备308转移至载体设备308和载体设备318之间的辊隙316，在该辊隙处基础结构102与连续长度的推进的前带406和后带408基底材料相结合。前带基底材料406和后带基底材料408各自限定面向穿着者表面312和相对的面向衣服表面314。第一带基底406的面向穿着者表面312可沿第一腰区116与基础结构102的面向衣服表面134结合，并且第二带基底408的面向穿着者表面312可沿第二腰区118与基础结构102的面向衣服表面134结合。如图4所示，在与离散的基础结构102结合之前，在辊318和载体设备308之间的辊隙316处，可将粘合剂320间歇地施加到第一带基底406和第二带基底408的面向穿着者表面312上。
参照图4和5D，连续长度的吸收制品400由多个离散的基础结构102限定，所述多个离散的基础结构沿纵向MD彼此间隔开并通过第二带基底408和第一带基底406彼此连接。如图4所示，连续长度的吸收制品400从辊隙316推进至折叠设备500。在折叠设备500处，在横向CD上沿侧向轴线126折叠每个基础结构102以将第一腰区116(具体地，内面向身体表面132)放置成与第二腰区118的内身体表面132成面对的、表面对表面的取向。基础结构的折叠也将在每个基础结构102之间延伸的第二带基底408的面向穿着者表面312定位成与在每个基础结构102之间延伸的第一带基底406的面向穿着者表面312成面对关系。如图4,5D和5E所示，与第一带基底406和第二带基底408连接的折叠的离散的基础结构102从折叠设备500被推进至粘结机设备334。粘结机设备334用来粘结重叠区域362，因此产生离散的粘结部位336a。重叠区域362包括在每个基础结构102之间延伸的第二带基底408的一部分和在每个基础结构102之间延伸的第一带基底406的一部分。如图4和5F所示，连续长度的吸收制品从粘结机334被推进至刀辊338，在该刀辊处沿横向切入区域336以产生吸收制品100上的第一侧缝178和在随后推进的吸收制品上的第二侧缝180。
虽然吸收制品被描述为具有第一带基底和第二带基底，但应当理解，吸收制品可具有仅一个带基底。另外，还应当理解，吸收制品的基础结构和带基底可为一个连续基底，使得重叠区域由相同的基底形成。因此，粘结机设备可用来在重叠区域粘结连续基底以形成一个或多个离散的粘结部位。
如前文所提及，参照图4，转换加工设备可包括粘结机设备334。例如，图6A示出了可用于本文的方法和设备的粘结机设备334的一个实施例的详细的示意性侧视图。如图6A所示，粘结机设备334可包括转筒364和邻近转筒364定位的砧辊368。砧辊368包括砧辊外圆周表面370并且适于围绕砧辊旋转轴线372旋转。转筒364也可包括转筒外圆周表面376并且适于围绕转筒旋转轴线374旋转。转筒364也可包括转筒外圆周表面376中的一个或多个转筒孔366。此外，多个接缝工位348定位在转筒外圆周表面376和转筒孔366的径向内侧。如下所更详述，参照图6B，每个接缝工位348可包括流体喷嘴378和压制构件380。虽然图6A所示的转筒364包括六个接缝工位348，但应当理解，转筒364可被构造成包括多于或少于六个接缝工位348。
在操作期间，转筒364可在图6A所示的方向上围绕转筒旋转轴线374旋转，并且砧辊368可在图6A所示的方向上围绕砧辊旋转轴线372旋转。吸收制品400可在纵向MD上推进到转筒外圆周表面376上，其中第一带基底406位于第二带基底408和转筒外圆周表面376之间。随着转筒364的旋转，接缝工位348的流体喷嘴378径向向外朝转筒外圆周表面376中的转筒孔366移动，如图6B所示。此外，将流体加热至足以至少部分地熔融重叠区域的温度。流体喷嘴引导受热流体的射流穿过转筒孔366并到达第一基底406和第二基底408的重叠区域上，其部分地熔融重叠区域362。随着转筒364继续旋转，流体喷嘴从转筒孔366径向向内回缩，转筒112继续围绕转筒旋转轴线374旋转，并且压制构件径向向外移位穿过转筒孔366。压制构件然后抵靠砧辊外圆周表面370压缩所述部分地熔融的重叠区域，从而在第一带基底406和第二带基底408之间产生一个或多个离散的粘结部位336a。随着转筒364继续旋转，压制构件从转筒孔366径向向内回缩。
如前文所提及，转筒的每个接缝工位均可包括流体喷嘴和压制构件。图7示出了接缝工位348的一个实施例的详细分解图。如图7所示，接缝工位348包括基座构件340，所述基座构件固定地与转筒连接并与其一起旋转。基座构件340为基本上正方形的并且由基座构件顶部表面382和基座构件底部表面383限定。基座构件340包括基座孔350，所述基座孔延伸穿过基座构件顶部表面382和底部表面383，使得流体喷嘴384和压制构件386可延伸穿过基座孔350。此外，基座构件底部表面383还固定地与基座联接件352连接。如下所述，基座联接件352的一个端部连接至基座构件底部表面383，并且基座联接件352的另一个端部可操作地连接至第一移位联接件354。
继续参见图7，接缝工位348也包括凸轮从动件构件358以及滚动地与凸轮从动件构件358连接的第一组凸轮滚柱388和第二组凸轮滚柱390。凸轮从动件构件358为基本上T形的，并且由凸轮从动件构件第一部分360、凸轮从动件构件第二部分362、和凸轮从动件构件顶面363限定。凸轮从动件构件第一部分360在凸轮从动件构件358上相同的位点可操作地与第一移位联接件354和第一组凸轮滚柱388连接。此外，第二组凸轮滚柱390在第一组凸轮滚柱388的径向外侧的位点可操作地与凸轮从动件构件第二部分362连接。一组第二移位联接件356也可操作地连接至凸轮从动件构件358。该组第二移位联接件356在第二组凸轮滚柱390相对外侧的位点将基座构件340可操作地连接至凸轮从动件构件第一部分360。
如下所更详述，参照图6A1和6B，第一组凸轮滚柱388和第二组凸轮滚柱390被构造成随着转筒364的旋转而沿固定式凸轮轨道滚动。固定式凸轮轨道293围绕着旋转轴线374并且由内圆周表面395和半径R限定，所述半径从固定式凸轮轨道392的内圆周表面395延伸至旋转轴线374，如图6A1所示。在一些实施例中，固定式凸轮轨道392可包括各种弯曲区和/或直区，使得固定式凸轮轨道392在沿固定式凸轮轨道392的内圆周表面395的不同点由相对较长和较短的半径R限定。第一组凸轮滚柱388和第二组凸轮滚柱390随着转筒364的旋转而在固定式凸轮轨道392上滚动。第一移位联接件354、第二移位联接件356、和第三移位联接件385枢转，其中固定式凸轮轨道392的半径R随着第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392的滚动而增加或减小。同时，在其中固定式凸轮轨道392由相对较长半径R限定的区域中，凸轮从动件构件385径向向外移位穿过基座孔。而在其中固定式凸轮轨道392由相对较短半径R限定的区域中，凸轮从动件构件径向向内移位穿过基座孔。应当理解，凸轮轨道392可被构造成具有各种其它形状和尺寸。例如，在一些实施例中，凸轮轨道392可被构造成具有相对于旋转轴线374偏移或偏心的圆形形状。从该旋转轴线偏移固定式凸轮轨道导致凸轮从动件构件随着第一组凸轮滚柱和第二组凸轮滚柱沿固定式凸轮轨道滚动而移位。
图8示出了接缝工位348的一个实施例的正视图。参照图7和8，接缝工位348可还包括弹簧构件394。弹簧构件394可为基本上U形的并且由弹簧构件顶面410、弹簧构件底面411、和弹簧构件侧开口412限定。参照图7，弹簧构件底面411固定地连接至凸轮从动件构件顶面363。弹簧构件394可沿整个凸轮从动件构件顶面363延伸。如下所更详述，弹簧构件侧开口412允许弹簧构件394随着压制构件抵靠砧辊外圆周表面压缩所述部分地熔融的重叠区域而挠曲。
如前所述，接缝工位也可包括压制构件380，如图7所示。压制构件380可为基本上矩形的形状，并且由压制构件顶面420、压制构件底面421、和压制构件长度387限定。压制构件380可包括基本上正方形的突出部423，所述突出部从压制构件顶面420向外延伸。压制构件421底面固定地连接至弹簧构件顶面410。压制构件380可沿整个弹簧构件顶面410延伸。如下所更详述，突出部423可被布置成两行，如图7所示。
继续参见图7，接缝工位348可也包括两个加热设备384。如下所更详述，每个加热设备384均提供加压流体源，所述加压流体源用于向例如流体喷嘴378递送受热的加压流体诸如空气。在一些实施例中，阀门可控制流体从加热设备384流出并进入到流体喷嘴378中。每个加热设备384均由一组第三移位联接件385可操作地连接至基座构件380。每个第三移位联接件385均可操作地连接至一个加热设备384的一个端部并且也连接至凸轮从动件构件第二部分365。
参照图7且如上所述，接缝工位也可包括流体喷嘴378。流体喷嘴378可包括一个或多个流体孔口424，在该流体孔口处从流体喷嘴378释放出受热的加压流体。每个加热设备384均固定地与分隔的流体喷嘴378连接。如图7所示，流体孔口424可为圆形的并且可成行地沿流体喷嘴378延伸。
如前所述，吸收制品在纵向MD上被推进至粘结机设备334。参照图6A，随着转筒364围绕转筒旋转轴线374旋转，吸收制品400在纵向MD上推进到转筒外圆周表面376上。第一带基底406位于第二带基底408和转筒外圆周表面376之间。更具体地，第一带基底406的外层162可直接与转筒外圆周表面376接触。并且第一带基底406的内层164可直接接触第二带基底408的内层164。转筒外圆周表面376以与推进的吸收制品400相同的速度行进，使得吸收制品400在转筒外圆周表面376上被接收的位点保持恒定，直到吸收制品400从转筒364下游被移除。第一带基底406和第二带基底408的重叠区域定位在与转筒孔366一致的转筒外圆周表面376上。如下所更详述，位于转筒孔366的径向内侧的接缝工位348被构造成随着吸收制品400沿转筒364行进而粘结重叠区域的一部分。接缝工位348被布置成随着吸收制品被接收在转筒364上而处于第一构型。
图9示出了处于第一构型的接缝工位348的一个实施例的透视图。参照图8和9，在第一构型中，流体喷嘴378定位成径向向外靠近转筒孔366和转筒外圆周表面376，而压制构件380定位成径向向内远离转筒孔366和转筒外圆周表面376。此外，流体喷嘴378还定位在与压制构件386的突出部423相同的圆周位置，使得受热流体被引导至重叠区域上相同的位置，所述重叠区域随后将被压制构件380压缩。
参照图6A和6B，随着转筒364继续旋转，吸收制品400围绕转筒外圆周表面376包裹。同时，受热的加压流体的射流从加热设备384被引导出流体喷嘴378并到达第一带基底406和第二带基底408的重叠区域上。保持流体喷嘴378与第一带基底406的外层162相距预选距离Y以控制由受热流体施加于重叠区域的压力，如图6B1所示。在一些实施例中，第一带基底406的外层162和流体喷嘴378之间的距离Y可保持在所述预选距离Y的3mm内。
随着流体加热重叠区域，可使用位置控制设备将吸收制品保持在与转筒的外圆周表面相距的恒定距离内。在一些实施例中，位置控制设备450可为带设备451，如图6C所示。位置控制设备450可位于邻近转筒364处并且可采用转筒外圆周表面376的至少一部分的形状。位置控制设备可使吸收制品400保持在与转筒的外圆周表面相距的0毫米至约10毫米的范围内，或与转筒外圆周表面相距在约0.5毫米至约5毫米之间。
一旦重叠区域被至少部分地熔融，并且随着转筒364继续旋转，接缝工位移位至第二构型。参照图6A，6A1，6B和6B1，如前所述，第一组凸轮滚柱388和第二组凸轮滚柱390随着转筒364的旋转而在固定式凸轮轨道392上滚动。当第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392滚动时，固定式凸轮轨道392保持固定。随着第一组凸轮滚柱388和第二组凸轮滚柱390从其中固定式凸轮轨道392的半径R由相对较短半径R限定的区域滚动至其中固定式凸轮轨道392的半径R由相对较长半径R限定的区域，第一移位联接件354、第二移位联接件356、和第三移位联接件385枢转。参照图6B，第一移位联接件354在基座联接件352和凸轮从动件构件358处枢转，而该组第二移位联接件356在凸轮从动件构件358和基座构件340处枢转。同时，凸轮从动件构件358径向向外朝转筒外圆周表面376移位。第三移位联接件385也在凸轮从动件构件358处枢转，导致加热设备384远离转筒外圆周表面376径向向内移动，并且导致流体喷嘴378在圆周上彼此隔开地铺展在压制构件380的任一侧上。接缝工位348继续移位，直到第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392的区域滚动，在所述区域中固定式凸轮轨道392的半径R保持恒定，这对应于接缝工位348的第二构型。接缝工位348保持在第二构型，直到第一组凸轮滚柱388和第二组凸轮滚柱390沿固定式凸轮轨道392行进至其中固定式凸轮轨道由相对较短的半径限定的区域。
图10示出了处于第二构型的接缝工位348的一个实施例的透视图。参照图10，在第二构型处，压制构件380延伸穿过转筒孔而超过转筒外圆周表面，加热设备384定位成向向内远离转筒孔366，并且流体喷嘴378邻近转筒外圆周表面366定位在凸轮从动件构件的任一侧上。
参照图6A和6B，当转筒364继续旋转并且接缝工位348处于第二构型时，所述部分地熔融的重叠区域接近位于邻近转筒364处的砧辊368。随着吸收制品400在砧辊368和转筒364之间通过，延伸穿过转筒孔366的压制构件380抵靠砧辊外圆周表面370压缩所述部分地熔融的重叠区域。
压制构件380的突出部423被构造成接触重叠区域的相同的位置，所述重叠区域如图6B所示被受热流体至少部分地熔融，因此在重叠区域中形成离散的粘结部位336a。弹簧构件394可用来向压制构件380和砧辊368之间的重叠区域施加预先确定的力。一旦被压缩，吸收制品就推进而脱离转筒外周边。转筒继续旋转，并且接缝工位移位回到第一构型以便在后续的吸收制品中形成离散的粘结部位。
在一些实施例中，粘结设备可用多次重复过程来压缩重叠区域以形成离散的粘结部位。例如，如图6D所示，在第一次压缩重叠区域之后，随着吸收制品400邻近第二砧辊371推进，接缝工位348从第一构型移位回到第二构型，从而第二次压缩重叠区域。应当理解，可使用多个砧辊，并且接缝工位348可从第一构型至第二构型来回移位从而多次压缩重叠区域。
图11示出了粘结机设备334的示意图，其突显出了围绕转筒364的接缝工位348的各种构型。如图11所示，单独的接缝工位处于第一构型430以便围绕转筒364旋转大约180度。接着，每个接缝工位都经过移位构型432，其中接缝工位从第一构型移位至第二构型以便围绕转筒364旋转大约六十度。然后每个接缝工位处于第二构型434以便围绕转筒364旋转大约六十度。最后，每个接缝工位通过复位构型436转变，其中接缝工位从第二构型移位至第一构型以便围绕转筒364旋转大约六十度。应当理解，接缝工位可处于每种构型以便以比图11所示的更大或更小的旋转度数围绕转筒364。
图12示出了具有处于第一构型的接缝工位348的粘结机设备334的示意性侧视图。如图12所示，当吸收制品400被接收在转筒364上时，接缝工位348处于第一构型。如图13所示，接缝工位348以大约180度从第一构型转变至第二构型，吸收制品400从那里被接收在转筒364上。
图14示出了带有处于第二构型的接缝工位348的粘结机设备334的示意性侧视图。如图14所示，接缝工位348处于第二构型以便围绕转筒364以大约六十度旋转。如图15所示，在吸收制品400被推进而脱离转筒364之后并且在后续的吸收制品400被接收在转筒364上之前，接缝工位348从第二构型复位至第一构型。
应当理解，可按各种方式来构造接缝工位。例如，图16示出了接缝工位348的一个实施例的正视图，其中第三移位联接件426可操作地连接至凸轮从动件构件358和加热设备384。第三移位联接件426可操作地连接至凸轮从动件构件358，使得在加热设备384的每个端部，第三移位联接件426看起来是交叉路径。
在一些实施例中，从该吸收制品至流体喷嘴的距离可在0毫米至约20毫米，或在约0毫米和例如约5毫米之间，或在约0.5毫米和约3毫米之间的范围内。控制第一基底和第二基底与流体孔口424之间的距离也可在加热过程中导致相对更可预测的流体喷涂和熔体图案。
受热流体可包括环境空气或其它气体。应当理解，所述流体可被加热至各种温度并被加压至各种压力。例如，在一些实施例中，流体可被加热高达范围为第一带基底和第二带基底的较低熔点减30℃至第一带基底和第二带基底的较低熔点加100℃的温度。在一些实施例中，流体压力可在0.1×105牛顿/平方米至1×106牛顿/平方米的范围内。在一些实施例中，可朝第一带基底和第二带基底至少一个引导受热流体并持续范围为10毫秒至1000毫秒或更长的时间间隔。可使用更短或更长的时间间隔。
在一些实施例中，压制构件可按在约1×105牛顿/平方米至约1×108牛顿/平方米范围内的压力抵靠砧辊外圆周表面压缩所述部分地熔融的重叠区域。在一些实施例中，压制构件366可压缩第一带基底和第二带基底并持续范围为10至1000毫秒或更长的时间段。可使用更短或更长的时间间隔。
虽然图9示出了每个加热设备和流体喷嘴为一个连续的元件，但应当理解，可使用多个加热设备和流体喷嘴。例如，图9所示的每个加热设备可包括两个或更多个单独的加热设备，每个加热设备均具有流体喷嘴。例如，单独的加热设备和对应的流体喷嘴可被设计成在不同的温度和压力下向重叠区域上的不同位置提供受热流体。例如，第一带基底和第二带基底的一些部分可具有与第一带基底和第二带基底的其它部分相比不同数目的材料和层，并且不同的材料可具有不同的熔点温度。通过选择性地用较高压力或较低压力或在较高温度或较低温度下来加热部分，带有较少层或较低熔点的材料的基底的部分将不被过度加热，并且带有较多层或较高熔点的材料的基底的部分将不被不足加热。
如图9所示，每个流体喷嘴378可具有一行基本上圆形的流体孔口424。然而，应当理解，流体孔口424可被布置成各种构型。此外，还应当理解，流体孔口可具有椭圆形、正方形、或各种其它形状。流体孔口424可具有范围为约0.1毫米至约6毫米的直径。
如图10所示，压制构件380可包括基本上正方形的突出部423，所述突出部以两行从压制构件顶面420延伸。然而，应当理解，突出部423在各种构型中可规则地或不规则地间隔开，并且可在各种方向上取向。突出部423可具有圆形、椭圆形、或各种其它形状。参照图10，突出部423可具有在约0.5毫米至约5毫米范围内的高度440。在一些实施例中，突出部可具有在约2毫米至约10毫米，或在约4毫米至约6毫米之间的范围内的宽度442。
虽然图8和10示出了弹簧构件390具有U形状，但应当理解，可使用各种其它弹簧构件来吸收出自压制构件386的压力，所述压制构件压缩砧辊外圆周表面之间的重叠区域。通过控制施加于重叠区域的力的量，有可能施加足以形成离散的粘结部位的力以最小化对基底的损害和/或尽量避免形成相对弱的离散的粘结件。
在一些实施例中，压制构件和砧辊可为涂覆的以防止所述至少部分地熔融的重叠区域粘着到压制构件和砧辊的表面上。压制构件和砧辊可涂覆有，例如等离子体涂层、聚四氟乙烯、或硅氧烷。在一些实施例中，压制构件的突出部可具有平滑表面使得离散的粘结部位将是平坦的。然而，在一些实施例中，压制构件的突出部可具有粗糙表面使得离散的粘结部位将具有纹理。
虽然图11示出了压制构件386沿压制构件长度387为连续的，但应当理解，压制构件386可沿压制构件386的宽度为不连续的使得压制构件386的多个片段可限定压制构件长度387。在一些实施例中，压制构件的多个片段可独立地用来以不同大小的压力压缩重叠区域。例如，压制构件386的每个片段可具有单独的弹簧构件394，其中每个弹簧构件394被设计成向重叠区域的不同部分施加不同大小的力。通过在不同的位置施加不同大小的力，有可能沿重叠区域穿透不同数目的基底层或材料进行粘结。通过选择性地用较大的力或较小的力来压缩部分，具有较少层或不同材料的基底的部分将不被过度压缩，并且具有较多层或不同材料的基底的部分将不会欠压缩。在一些实施例中，压制构件可沿压制构件长度387具有不同成型的突出部，或可具有多于一个片段，其中每个片段具有不同成型的突出部，或可沿压制构件长度具有不同构型的突出部。
一旦选择了标称设定点，流体的温度和压力就保持在指定范围内。例如，可从上述范围选择设定点，因而温度可保持在围绕标称设定点的固定范围内，诸如±30℃；并且压力可保持在围绕标称设定点的固定范围内，诸如±1巴。可接受的范围将取决于要接合的材料的属性诸如软化点和/或熔融温度和所选择的标称设定点之间的关系。例如，高于要接合的材料中的一者或多者的熔融温度的标称设定点与远远低于要接合的一种或多种材料的熔融温度的标称设定点相比可能需要较紧密的控制范围。控制范围可为关于标称设定点非对称的。所谓足够地加热，是指流体被加热至将使得一个基底或多个基底能够至少部分地熔融或至少软化的温度。足够的加热可随着所用的材料和设备而有变化。例如，如果几乎立即将受热流体施加于一个基底或多个基底而只有极少时间或没有时间冷却，则可将流体加热至一个基底或多个基底的大约软化点或大约熔点。如果在经过了某段时间或距离之后将受热流体引导至一个基底或多个基底，使得受热流体在与一个基底或多个基底相互作用之前可在一定程度上冷却，则可能有必要将流体加热至高于(有可能显著地高于)一个基底或多个基底的软化点或熔点。
也可利用脉冲化施加方式将流体递送至重叠区域。可调节受热流体的射流的影响，使得由该射流所引入的能量加上由其它装置诸如受热的砧辊(如果砧辊受热的话)、流体喷嘴、重叠区域的变形、以及第一带基底和第二带基底的内摩擦所引入的能量足以至少部分地熔融第一带基底和第二带基底中的可熔融组件以产生某种粘著性，所述粘著性在压缩时将形成强效接头。可熔融组件的熔融可在整个第一带基底和第二带基底中按非均匀方式发生。
本文所述过程中的能量传递的持续过程可为动态过程，并且可产生横跨可熔融组件的横截面的温度梯度。即，可熔融组件的芯可保持为固体，而可熔融组件的外表面熔融或接近熔融。甚至在低于熔融温度时，所述外表面也可达到软化点，使得与相同的材料在环境温度下相比，材料的塑性变形可在低得多的负荷下发生。因此，如果要接合的材料中的一者或多者具有软化点，则可调节该过程以在第一带基底406和第二带基底408的至少一部分中获得在软化点和熔点之间的温度。使用等于或高于可熔融组件中的一者或多者的软化点但低于熔点的温度可允许在第一带基底406和第二带基底408之间产生强效粘结，而对可熔融组件的结构的破坏(例如，拉细或换句话讲弱化可熔融组件)较小。
粘结机设备在第一带基底和第二带基底的一些部分中或围绕这些部分对热能进行配量和分散，在所述部分中将形成离散的粘结部位。所传递的用以形成离散的粘结部位的热能越低，则该过程损害附近材料或影响邻近所预期的离散的粘结部位的层的可能性就越小。受热流体的射流可分散穿过多孔层；或在第一带基底和第二带基底的熔融温度不相同的情况下，可使用热空气来形成透过第一外表面的孔，从而允许所述热空气渗透至第二外表面。在第一带基底和第二带基底各自为多孔的并且第一带基底和第二带基底具有基本上相同的熔融温度的情况下，则可使用相对低温度、低压力的流体流，从而几乎不损害离散的粘结部位中的纤维及它们周围的纤维。在一些情况下，如果第一带基底和第二带基底中的一者或在热流体源与第一带基底和第二带基底之间的另一个材料层不是多孔的或所具有的熔融温度不是与其它层基本上相同的，则可能需要相对高温度、高压力的流体流。
如上所述，该方法可还包括如下步骤：在可熔融组件被至少部分地熔融的同时，和/或在发粘状态中，用压制构件压缩重叠区域。压制构件的温度可至少低于第一带基底和第二带基底的熔点。在一些实施例中，可加热压制构件。可熔融组件的粘着属性允许第一带基底与第二带基底接合，因此，可减少或避免熔融的纤维网材料的积聚。可根据例如审美标准来设计压制构件，从而提供离散的、成型的点，在该点处第一带基底和第二带基底被接合。如果需要的话，离散的粘结部位可被构造成使得接缝相对更容易打开。压缩点大致可采用压制构件的突出部的形状和间距。作为一个例子，压制构件的突出部可为大致椭圆形的，或可具有符合所期望的移除力和对移除力感知的任何其它几何形状或装饰性形状。压制构件的突出部可为规则地或不规则间隔的，并且可在各种方向上取向。
参照图4和5f，一旦形成了离散的粘结部位336a，吸收制品400就在纵向MD上推进至刀辊338，在该刀辊处沿横向切入区域336以产生吸收制品100上的第一侧缝178和随后在推进的吸收制品上的第二侧缝180。在一些实施例中，应当理解，刀辊可与压制构件成一体的，使得当压制构件压缩重叠区域时，压制构件也切割重叠区域。
虽然是在粘结带以制备侧缝的上下文中描述粘结设备的，但应当理解，本文的方法和设备可用来将各种组件和基底粘结在一起。本文的粘结设备和方法也可被构造成根据美国专利6,248,195和2010年6月7日提交的美国专利申请公布2012-0021186所公开的设备和方法来操作。
本文所公开的量纲和值不可理解为严格限于所引用的精确值。相反，除非另外指明，每个这样的量纲旨在表示所述的值以及围绕该值功能上等同的范围。例如，所公开的量纲“40mm”旨在表示“约40mm”。
除非明确排除或换句话讲有所限制，本文中引用的每一个文件，包括任何交叉引用或相关专利或专利申请，均据此以引用方式全文并入本文。任何文件的引用并非是对其相对于本发明所公开的任何发明或受权利要求书保护的本文，或其单独，或以与任何其它参照或参考文献、教导、建议或公开的任何此类发明的任何组合的现有技术的认可。此外，如果此文献中术语的任何含义或定义与任何以引用方式并入本文的文献中相同术语的任何含义或定义相冲突，将以此文献中赋予那个术语的含义或定义为准。
尽管举例说明和描述了本发明的特定实施例，但对本领域的技术人员来讲显而易见的是，在不背离本发明的实质和范围的情况下可作出许多其它的改变和变型。因此，随附权利要求书旨在涵盖本发明范围内的所有此类改变和变型。

Claims (14)

1.一种用于形成接缝的方法，所述方法包括以下步骤：
围绕旋转轴线(374)旋转转筒(364)，所述转筒(364)包括流体喷嘴(378)和压制构件(380)；
旋转邻近所述转筒(364)的砧辊(368)；
在纵向上将第一基底(406)推进到所述转筒(364)上，所述第一基底(406)具有内表面和外表面，其中所述第一基底的所述外表面邻近所述转筒(364)；
在所述纵向上推进第二基底(408)，其中所述第一基底(406)位于所述第二基底(408)和所述转筒(364)之间；
围绕所述转筒(364)的一部分包裹所述第一基底(406)和第二基底(408)；
将流体加热至足以至少部分地熔融所述第一基底(406)和第二基底(408)的温度；
从所述转筒(364)径向向外移动所述流体喷嘴(378)；
将所述受热流体的射流引导到所述第一基底(406)和第二基底(408)上；
部分地熔融所述第一基底(406)和第二基底(408)；
将所述流体喷嘴(378)径向向内回缩到所述转筒(364)中；
从所述转筒(364)径向向外移位所述压制构件(380)；以及
在所述压制构件(380)和所述砧辊(368)之间压缩所述第一基底(406)和第二基底(408)。
2.根据权利要求1所述的方法，其中所述转筒(364)包括转筒外圆周表面(376)和所述转筒外圆周表面(376)中的转筒孔(366)，并且其中所述流体喷嘴(378)和压制构件(380)位于所述转筒外圆周表面(376)中的所述转筒孔(366)的径向内侧。
3.根据权利要求2所述的方法，还包括使用位置控制设备(450)将所述第一基底(406)和第二基底(408)保持在与所述转筒外圆周表面(376)相距某一距离内的步骤。
4.根据权利要求1所述的方法，还包括使用位置控制设备(450)将所述第一基底(406)和第二基底(408)保持在与所述转筒(364)相距某一距离内的步骤。
5.根据前述权利要求中任一项所述的方法，还包括将所述流体喷嘴(378)保持在与所述第一基底(406)相距某一距离(Y)的步骤。
6.根据权利要求5所述的方法，其中从所述流体喷嘴(378)至所述第一基底(406)的所述距离(Y)在0毫米至10毫米的范围内。
7.根据权利要求1-4和6中任一项所述的方法，其中所述受热流体的射流所处的温度范围为从所述第一基底(406)和第二基底(408)的较低熔点减30℃至所述第一基底(406)和第二基底(408)的较低熔点加100℃。
8.根据权利要求1-4和6中任一项所述的方法，其中所述受热流体的射流以0.1×105牛顿/平方米至1×106牛顿/平方米范围内的压力被引导在所述第一基底(406)和第二基底(408)处。
9.根据权利要求1-4和6中任一项所述的方法，其中所述受热流体的射流在10毫秒和1000毫秒之间被引导在所述第一基底(406)和第二基底(408)处。
10.根据权利要求1-4和6中任一项所述的方法，其中所述压制构件(380)在所述砧辊(368)之间以1×105牛顿/平方米至1×108牛顿/平方米的压力压缩所述第一基底(406)和第二基底(408)。
11.一种用于将基底粘结在一起的设备，所述设备(334)包括：用于连续地推进第一基底(406)和第二基底(408)的转筒
(364)，所述转筒(364)包括转筒外圆周表面(376)和在所述转筒外圆周表面(376)中的转筒孔(366)，其中所述转筒(364)适于围绕旋转轴线(374)旋转；
可移动地连接至所述转筒(364)的流体喷嘴(378)，所述流体喷嘴位于所述转筒孔(366)的径向内侧并且适于径向向外朝所述第一基底(406)和第二基底(408)引导流体穿过所述转筒孔(366)；
位于邻近所述转筒(364)处的砧辊(368)，所述砧辊(368)适于围绕旋转轴线(372)旋转；和
可移动地连接至所述转筒(364)的压制构件(380)，所述压制构件位于所述转筒孔(366)的径向内侧，并且适于延伸穿过所述转筒孔(366)以在所述砧辊(368)之间压缩所述第一基底(406)和第二基底(408)，从而形成粘结件。
12.根据权利要求11所述的设备，还包括连接至所述转筒(364)的固定式凸轮轨道(293)。
13.根据权利要求12所述的设备，还包括与所述固定式凸轮轨道(293)连接的凸轮滚柱(388，390)，所述凸轮滚柱(388，390)适于径向向内和向外移位所述流体喷嘴(378)和压制构件(380)。
14.根据权利要求13所述的设备，还包括连接至所述压制构件(380)的弹簧构件(394)，其中所述弹簧构件(394)适于通过所述压制构件(380)向所述第一基底(406)和第二基底(408)施加力。
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