CN104302257A - Apparatus and process for aperturing and stretching a web - Google Patents

Abstract

Apparatuses and processes for aperturing and stretching a web are disclosed. In one embodiment, the method involves feeding a web into a nip that is formed between at least one pair of intermeshing rolls. The first roll is a raised ridge rotary knife aperturing roll and the second roll is a ring roll; both rolls comprise ridges and grooves. The first roll comprises a plurality of spaced-apart teeth extending outwardly from the top surface of the ridges, said teeth having tips, wherein the top surface of said ridges are disposed between the tips of said teeth and the bottom surface of said grooves. These apparatuses and processes enable a web to be formed which comprises apertures having greater open area than previously achievable with traditional processes and apparatuses.

Description

For carrying out equipment and the method for perforate and stretching to fleece

Technical field

The present invention relates to perforate web material and for fleece is carried out perforate and stretch with the equipment and the method that form this type of material.

Background technology

Disclose for carrying out perforate to fleece in patent documentation, distortion and/or the various method and apparatus stretched.When utilizing boring method such as hobboing cutter perforate, be difficult to produce the fleece with very little hole, interval, wherein this some holes has desired width on horizontal (" CD ").Be close together in order to hole rows is partitioned into, the activation tooth with very little angle can be provided.But this method can bring problem, because the hole produced does not have enough hole widths in the horizontal, be also even like this under the high depth of engagement (activation discaling roll is to the interference of pairing ring roller).The hole of gained is usually extended in the vertical, thus causes slit sample outward appearance, low aperture area and potential stress to be concentrated, thus in use causes tearing.More tough and tensile and when having more the fleece of tear resistance when adopting, the especially individual problem of generation in the hole of slit sample, low aperture area.Sphering or the hot pin perforate of convergent be common method, but it has the shortcoming needing counter roller to have larger alignment precision, and it causes larger pitch of holes usually.Sphering or the hot pin perforate of convergent usually carry out with lower linear velocity.

Likely pillar ring-rolling is carried out to stretch it to perforate fleece, but the aperture size of alternate row may be caused, because hole can not with follow-up ring roller drawing process registration.Due to variable the sprawling of substrate, be difficult in the horizontal structure be aimed at technique subsequently.Pillar ring-rolling also may weaken fleece significantly, thus makes it be easier to tear.

Wish to produce a kind of fleece with discrete, that interval is very little hole, wherein this some holes has larger transverse width compared with previously possible hole.Need a kind of perforate fleece being more firmly thus not easy to tear in the horizontal in the horizontal.Need the fibroreticulate method of the following perforate of a kind of generation, the hole that described perforate fleece has more greatly, wider, opening is larger.Also need to allow fleece to be become to have the equipment in hole by perforate, described hole has desired larger width in the horizontal.

Exist many known to the fibroreticulate technique with ridge and groove, such as ring-rolling.Also exist many known to the fibroreticulate technique with hole, such as hot pin perforate.But be difficult to produce corrugated web, it has the ridge replaced and groove aimed at particular bore pattern.There is the technique of then carrying out ring-rolling for carrying out crack hole.But this causes the ripply smooth fleece of not tool.The fleece (smooth bar) with ridge and groove can be formed via jet on patterning belt or water spray.But compared with invention as herein described, jet or water spray is much slow technique and needs more energy.In addition, described ridge be not hollow thus can keep more fluid.

Wish to produce the fleece with ridge alternately and groove, its mesopore is arranged in the ad-hoc location of fleece, such as, is arranged in groove or is positioned at chi chung.Need a kind of perforate fleece comprising the wave pattern of aligning.

These are all targets of the present invention; Embodiment as herein described can realize the various combinations of these targets.Certain specific embodiment can but not necessarily implement each target.

Summary of the invention

The present invention relates to perforate and be usually corrugated web material, and for carrying out perforate to fleece to produce equipment and the method for this type of material.This type of material can be provided as the component of following product: such as absorbent article (such as top flat, egative film, acquisition layer, liquid handling layer, and absorbent cores), packaging (such as flow-wrapped, shrink wrapped and plastic bag), cleaning piece, medicated napkin, toilet paper, napkin etc.There is a large amount of non-limiting example of the present invention.

The present invention relates to a kind of equipment, this equipment is included in two the intermeshing shaped structures forming roll gap between the two, described equipment comprises: the first shaped structure, it comprises: multiple first ridge on the surface of shaped structure and the first groove, wherein said first ridge has top surface, and described first groove has lower surface; With isolated multiple tooth, described tooth stretches out from the top surface of described first ridge, and each tooth all can form hole, and the top surface of wherein said first ridge is between the end and the lower surface of described first groove of described tooth; With the second shaped structure, it comprises multiple continuous print second ridge and the second groove.

The invention still further relates to a kind of equipment, this equipment is included in two the intermeshing reverse rolls forming roll gap between the two, described equipment comprises the first roller of general cylindrical, described first roller has surface, circumference and axis, described first roller comprises: multiple circumferential first ridge on the surface of described roller and circumferential first groove, wherein said first ridge has top surface, and described first groove has lower surface; With isolated multiple tooth, described tooth stretches out from the top surface of described first ridge, and each tooth is from top surface to end convergent, and the top surface of wherein said first ridge is between the end and the lower surface of described first groove of described tooth; With the second roller of general cylindrical, described second roller comprises multiple continuous print circumference the second ridge and circumferential second groove.

The invention still further relates to a kind of technique using equipment that fleece is out of shape, this technique comprises in the roll gap of precursor web to be fed and being formed between two intermeshing rollers, described two intermeshing rollers comprise: a) the first roller of general cylindrical, described first roller has surface, circumference and axis, described first roller comprises: multiple first ridge and the first groove, described first ridge and the first groove extend on the surface of roller around the circumference of roller, wherein said first ridge has top surface, and described first groove has lower surface; With isolated multiple tooth, described tooth stretches out from the top surface of described first ridge, and described tooth has end, and the top surface of wherein said first ridge is arranged between the end of described tooth and the lower surface of described first groove; And the second roller of b) general cylindrical, described second roller comprises multiple continuous print circumferential ridge and circumferential recess, and wherein said second ridge has top surface, and described second groove has lower surface; Wherein when described fleece is fed in described roll gap, the top of at least some of the chi chung on the first roller extends inwardly to the degree of depth at the top of at least some of the second chi chung exceeded on described second roller towards the axis of described second roller, and described fleece:

(i) by described tooth in isolated multiple primary importance perforate to form isolated multiple hole; And

(ii) stretched by described intermeshing roller in the horizontal.

Accompanying drawing explanation

Comprise accompanying drawing herein so that understand the present invention better.Accompanying drawing shows invention as herein described, and is used for together with the description claimed theme is described.

Fig. 1 is the perspective view of a pair ring roller of prior art for making fleece be out of shape.

Fig. 2 A is the perspective view of the pair of rolls of the prior art for carrying out perforate to fleece, i.e. hobboing cutter perforate (or " RKA ") roller and ring roller.

Fig. 2 B is the side view of the roller of a pair prior art shown in Fig. 2 A.

Fig. 2 C is the enlarged side view of the roll gap between the roller shown in Fig. 2 A.

The exemplary prior art fibroreticulate top view of Fig. 2 D for being formed by the roller shown in use Fig. 2 A.

Fig. 3 A is the perspective view of the pair of rolls that can be used for equipment as herein described and method, and one of them roller is staggered " convex ridge " hobboing cutter perforate roller, and another roller is ring roller.

Fig. 3 B is the enlarged side view of the roll gap between the roller shown in Fig. 3 A.

Fig. 4 A is the perspective view of the part on the surface of exemplary convex ridge hobboing cutter perforate roller.

Fig. 4 B is the perspective view of the part on the surface of exemplary loop roller.

Fig. 4 C is the perspective view of the part on the surface of exemplary convex ridge structuring elastic-like film roller.

Fig. 5 A is the perspective view of the part on the surface of another exemplary convex ridge hobboing cutter perforate roller.

Fig. 5 B is the side view of the gear mutation shown in Fig. 5 A.

Fig. 5 C is the end-view of the gear mutation shown in Fig. 5 A.

Fig. 5 D is the top view of the gear mutation shown in Fig. 5 A.

The profile of Fig. 5 E for intercepting along the line D-D of the gear mutation shown in Fig. 5 B.

The profile of Fig. 5 F for intercepting along the line E-E of the gear mutation shown in Fig. 5 B.

Fig. 6 A is the front view of the first example teeth group, wherein these teeth be convergent and truncation.

Fig. 6 B is the front view of the second example teeth group, wherein these teeth be convergent and half truncation.

Fig. 6 C is the front view of the second example teeth group, wherein these teeth be convergent and non-truncation.

Fig. 7 is the schematic diagram of tooth pattern, wherein can realize end facet angle γ and ridge finishing in single helical form machining steps.

Fig. 8 is the enlarged side view of the part on the surface of alternative convex ridge hobboing cutter perforate roller.

Fig. 9 A is the top view by the fibroreticulate example using the modification of the roller in Fig. 3 A to be formed.

Fig. 9 B is the zoomed-in view in one of the hole shown in Fig. 9 A.

Figure 10 is the side view of another embodiment of equipment for carrying out perforate to fleece, and wherein three rollers are planetary arrangement.

Figure 11 is the top view (film be stretched/flattened to illustrate high basis weight regions and low basis weight regions) of 25gsm PE membrane fiber net.

Figure 12 is the top view (non-woven material be stretched/flattened to illustrate high basis weight regions and low basis weight regions) of 60gsm PP non-woven webs.

Figure 13 is the fibroreticulate profile shown in Figure 12.

Figure 14 is the side perspective view of another non-woven webs.

Figure 15 is the top perspective of non-woven webs.

Figure 16 is the profile of membrane fiber net.

Figure 17,18A and 18B are the fibroreticulate top view of apertured film described in example 1.

Figure 19 A is the top perspective of the apertured nonwoven web as described in example 2.

Figure 19 B is the fibroreticulate bottom perspective view of Figure 19 A.

Detailed description of the invention

Hereafter set forth the broad description of the numerous different embodiment of the present invention.It is only exemplary that this explanation is intended to be understood to, and and each possible embodiment of non-depicted because to describe each possible embodiment be impossible is also unpractical.And should be appreciated that any feature as herein described, characteristic, assembly, composition, composition, product, step or method all can be deleted, entirely or partly with any further feature as herein described, characteristic, assembly, compositions, composition, product, step or Combination of Methods or replaced by the latter.The technology that can use current techniques or develop after the submission date of this patent is to implement numerous alternative embodiment, and the described technology developed after the submission date of this patent will still belong to the scope of this claim.All announcements of quoting herein and patent are all incorporated herein by reference.

It should also be understood that, unless term use in this manual sentence " as used herein; term ' _ _ _ _ _ _ ' be defined as accordingly referring to ... " or similar sentence clearly defines, otherwise and also the clear of this term or impliedly restriction are exceeded its usual or common implication by not intended to be, and this type of term should not be interpreted as being limited within the scope of any statement (except the language of claims) done in any portion based on this patent.Be absolutely necessary for the purpose of the present invention without any term, unless specified like this.When in this patent in the mode meeting single implication to mention the arbitrary term described in this patent appended claims time, just for clarity not cause confusion to reader, and and this claim terms impliedly or is in other words restricted to this single implication by not intended to be.Finally, except non-claimed element does not describe any structure to define by description wording " device " and function, otherwise the scope that should be used for explaining arbitrary claim elements based on 35U.S.C. § 112 the 6th section is not intended.

The invention enables and can form a kind of perforate fleece being more firmly thus not easy to tear in the horizontal in the horizontal.The invention describes a kind of fibroreticulate technique of perforate for generation of having very little hole, discrete interval, described hole has desired larger width in the horizontal.This technique also can produce the structure with ridge alternately and groove, and its mesopore is included in groove.Invention also describes a kind of equipment, permission fleece is become to have in the horizontal the hole of the very little larger width in desired discrete interval by it by perforate.

As used herein, term " absorbent article " comprises disposable product, such as sanitary towel, sanitary pad, tampon, interlabial devices, wound dressing, diaper, adult incontinence product, cleaning piece etc.In addition, the absorption component produced by these method and apparatus disclosed herein is also applicable to other fleece such as scouring pad, and dry mop pads (such as pad) etc.At least some in this type of absorbent article is intended to for absorbing body fluid, such as through liquid or blood, vaginal secretions, urine and feces.Cleaning piece can be used for absorbing body fluid, or can be used for other object, such as clean surface.Above-mentioned various absorbent article will generally include the top flat of fluid permeable, the egative film of liquid impermeable joining top flat to and the absorbent cores between top flat and egative film.

As used herein, term " absorption component " refers to provides one or more liquid handling functions such as liquid acquisition usually, Liquid distribution, liquid transfer, the assembly of the absorbent article of fluid storage etc.If absorption component comprises absorbent cores assembly, then this absorption component can comprise an only part for whole absorbent cores or this absorbent cores.

As used herein, term " hole " refers to hole.Hole can rush cleanly and wear fleece, the material of surrounding hole is made to be arranged in the plane (" two dimension " hole) identical with fleece before hole is formed, or formation hole, be wherein pulled to outside fibroreticulate plane around at least some in the material of described opening.In the case of the latter, this some holes can be similar to " three-dimensional " hole.Three-dimension hole keeps larger aperture area in applied load as next.As used herein, term " perforate " refers to the fleece comprising multiple hole.

As used herein, " assembly " of term absorbent article refers to each component of absorbent article, such as top flat, acquisition layer, liquid handling layer, absorbent cores or absorbent core layer, egative film, and barrier such as barrier layer and obstruct hoop.

As used herein, term " corrugated " or " ripple " refer to and comprise the almost parallel multiple ridge replaced and the three-dimensional network shape characteristic of groove, and its median ridge and groove rise and fall around (flatly drawing through fibroreticulate cross section) axis X.Ridge and groove can rise and fall comparably on the either side of axis, or can lopside.

As used herein, term " transverse direction " or " CD " refer to the path perpendicular to longitudinal direction in fibroreticulate plane.

As used herein, term " deformable material " is for changing the material of its shape or density in response to applied stress or strain.

As used herein, term " depth of engagement " (" DOE ") refers to the mesh degree between two rollers.This distance measures outermost end to the tooth on the second roller or ridge from the outermost end of the tooth the first roller or ridge.As used herein, term " engagement " or " engaging each other " refer to following arrangement: the tooth/ridge at this moment on one of roller extends towards the surface of another roller, and extend between the tooth/ridge of the some parts of at least some of these tooth/chi chungs on the surface of another roller and the below of imaginary plane that draws of the end being positioned at the tooth/ridge on the surface of another roller.

As used herein, term " discrete " refers to different or does not connect.When being relevant to the tooth on convex ridge roller and using term " discrete ", it refers to that (or radially) far away end of tooth (comprises in machine and transverse direction) in all directions and is different or that do not connect (even if the base portion of tooth can be shaped as the identical surface of such as roller).Such as, the ridge on ring roller is not considered to discrete.

As used herein, term " disposable " describe and not intended to be washed recover or the absorbent article that re-uses as absorbent article or product and other products (namely, they are intended to be dropped after a procedure, and be preferably recovered utilization, compost treatment or in other words with the mode process of environmentally compatible).

As used herein, term " hollow " is described through existing ridge and groove in fleece prepared by equipment as herein described and method.Ridge and groove comprise the neutral gear without web material.Such as, fleece comprises ridge, groove, and flatly through X-axis line that fibroreticulate cross section draws; To be positioned at above X-axis line but the region be positioned at below crestal culmination portion is hollow, or to comprise the region of hollow.Equally, to be positioned at below X-axis line but the region be positioned at above bottom portion of groove is hollow, or to comprise the region of hollow.

As used herein, term " longitudinal direction " or " MD " refer to the path that material such as fleece advances along whole manufacture process.

As used herein, when term " macroscopic view " refers to that the vertical dimension between the eyes and fleece of observer is about 12 inches (30cm), can people's easily visible and obvious recognizable architectural feature or element of 20/20 vision be had.On the contrary, as used herein, term " microcosmic " refers to the feature being not easy to see in this type of condition and can not obviously distinguishing.

As used herein, term " ring roller " or " ring-rolling " refer to the technique using deformation element, described deformation element comprises the reverse roll of at least some part containing continuous print ridge and groove, engage each other band, or engage each other plate, wherein the intermeshing ridge (or protuberance) of deformation element and groove (or depressed part) engage and the fleece inserted between them that stretches.Except as otherwise noted, ring roller is not separately to fleece perforate.For ring-rolling, depend on the orientation of ridge and groove, deformation element can be arranged to laterally, in longitudinal direction or in the hand of spiral/to stretch at angle fleece with transverse direction or longitudinal direction.Example about a direction as herein described is intended to the direction being understood to be applicable to non-depicted.

As used herein, term " hobboing cutter perforate " (RKA) refers to the method and apparatus using intermeshing deformation element or roller, and wherein one or more rollers comprise multiple tooth.Tooth can be sharp-pointed wear fleece to cut and make fleece be out of shape thus produce perforate fleece, or in some cases, produces three-dimensional open pores fleece, disclosed in US 2005/0064136A1 and US 2006/0087053A1.

Term " structuring elastic-like film " or " structuring class elasticity film forming " refer to Procter & Gamble technology, wherein SELF (structuring elastic-like film) representative structural elastic like film.Method, equipment and the pattern via the generation of structuring class elasticity film forming illustrate and are described in United States Patent (USP) 5,518,801; 5,691,035; 5,723,087; 5,891,544; 5,916,663; 6,027,483; With in 7,527,615B2.Although this technique was originally make polymeric film be out of shape and the tooth geometry that do not produce hole develops, but develop other tooth geometry, they are more conducive to forming bunch (with regard to non-woven material), or on front-end and back-end, have the tent-shapaed parts (with regard to film) in hole.Use structuring class elasticity membrane formation process to be formed in non-woven webs to have hole bunch technique be disclosed in United States Patent (USP) 7,682,686B2.

As used herein, term " tooth " refers to can to any element on the roller surface of fleece perforate.

i. perforate web material

Although there is used herein term " perforate web material ", object is by the assembly such as absorption component (or non-absorbing component) of this class perforate web material generation for absorbent article.In such cases, each assembly (such as top flat, egative film, acquisition layer, absorbent cores) that will be cut into for absorbent article of perforate web material.With regard to the fleece for absorbent article, this type of new construction can be included in fibroreticulate predetermined part those that provide the characteristic of improvement (flexibility such as improved, fluid treatment, or other characteristic).These perforate fleeces can be cut other assemblies various (such as, flow-wrapped, shrink wrapped and plastic bag) forming the product for encapsulating, cleaning piece, medicated napkin, toilet paper, napkin etc.

Can be provided in the hole that the discrete interval in a lateral direction with larger width is very little in fleece and the assembly formed by them, described hole impossible produce with current method and mould.Compared to the hole (see Fig. 2 D) of the equivalent aperture area that can obtain via prior art, new bore comprises larger aperture area and lower aspect ratio (hole length: hole width), and this (with regard to film) causes fleece intensity to increase.

In addition, also there is with the fleece that this new technique produces the outward appearance of unique more veining.The fleece of described veining can comprise ridge alternately and groove, and its mesopore is included in groove wittingly.With regard to the perforate fleece for absorbent article, fleece can provide better fluid acquisition, breathability, or with being separated of health, thus promote dryer and comfortableer, more clean sensation.Such as, in sanitary towel, the hole being arranged in groove helps guide fluid and fluid is transferred to lower absorbent component from top flat.Not only hole provides these beneficial effects, and any ripple be present in final fleece also can support these beneficial effects in addition.Such as, ripple provides at least part of noncontact with health, which improves breathability, produces dry and comfortable sensation, and contribute to less contacting may chafe or moistening/dirty surfaces that people is done not feel like oneself.With regard to sanitary towel, ripple can guide fluid along sanitary towel in the vertical and keep fluid away from the lateral edges of sanitary towel.

Any suitable deformable material can be comprised, such as weaving material, non-woven material, film, flat film, the film of microtexture, the combination of any previous materials or lamilated body by by the fleece of perforate (or " precursor web ")." non-woven webs " refers to following fleece as the term is employed herein: described fleece has the structure of single fiber or the line be caught in the middle, but be not that described weaven goods or knitted fabric do not have randomly-oriented fiber usually as the repeat patterns in weaven goods or knitted fabric.Non-woven webs can comprise or can not comprise hot sticky node.This can comprise ground paper, such as thin paper, dry pulp material, liner plate, filter paper and their combination.Non-woven webs or fabric are formed by much technique, and such as, molten blowing method, spun-bond process, water acupuncture manipulation, air lay, wet-laying, aeration-drying paper technology and bonding carded fibers network process, comprise carded thermal bond.Depend on forming technology, non-woven webs or can not comprise hot sticky node.Membrane material can be monolayer, multilamellar, impression or microtexture.Described Woven fabric, supatex fabric, film, combination or layered product can be made up of any suitable material, include but not limited to natural material, synthetic material and their combination.Suitable natural material includes but not limited to cellulose, velveteen, bagasse, wool fibre, silk fiber etc.In certain embodiments, web material can be substantially free of cellulose, and/or does not comprise paper material.In other embodiments, method as herein described can be performed to containing cellulosic precursor material.Suitable synthetic material includes but not limited to artificial silk and polymeric material.Suitable polymeric material includes but not limited to: polyethylene (PE) (such as, linear low density polyethylene (LLDPE), Low Density Polyethylene (LDPE), high density polyethylene (HDPE) (HDPE) etc.), polyester, polyethylene terephthalate (PET), and polypropylene (PP).Any one in above-mentioned material all can comprise after consumption can the material of recirculation.Equipment as herein described is applicable to far-ranging material and lower-cost material.Such as, daily viscose non-woven material can be used, there are multiple layers of different chemical and mechanical property (and controlling degree of described two or more layers of mixing mutually), there is the non-woven material of various fiber prescription & formation; Or film.In addition, this equipment can also run (and not losing loft because of roll compaction/storage) by direct-on-line.

Various polymer all can be used for producing interested fleece.Potential material comprises biopolymer, this biopolymer is made up of non-petroleum sources, such as biologically-derived polyethylene (bio-PE), biologically-derived polypropylene (bio-PP), biologically-derived polyethylene terephthalate (bio-PET) and biologically-derived poly-(FDCA glycol ester) (bio-PEF).These materials can partially or even wholly derived from least one Renewable resource, and wherein Renewable resource refers to the natural resources that can regenerate within 100 years.Renewable resource comprises plant, animal, Fish, antibacterial, fungus and forestry products, and can be the biology of naturally occurring, crossbred or genetic engineering.The natural resources such as crude oil, coal and the peat that need the cost time longer than 100 years to be formed are not considered to Renewable resource.Other polymer deriving from non-petroleum sources comprises starch-based polymer and cellulose.In addition, can use 100% or with various kinds of resin blended can recycled resin, as r-HDPE, r-LLDPE, r-LDPE, r-PET, r-PEF or r-PP of pulverizing again after consumption.Derive from Renewable resource and can the polymer of recycled resin can independently use, or being mixed into petroleum base polymer to control cost with different content.The source of polymer is prepared and method is found in US 8,063,064 B1 and US 2011/0319849 A1 by non-petroleum sources.

The present invention relates to perforate web material and for carrying out perforate to fleece and stretching with the equipment and the method that produce this type of material, described equipment and method overcome in the shortcoming of prior art one or more.It is useful for stretching or stretching fleece, reduces costs because it makes it possible to by reducing fibroreticulate basic weight on the whole.By carrying out perforate and stretching in identical processing step, in web material, produce wider, preferred hole.Herein, perforate and stretching are carried out with alignment in single unit, described stretching being carried out during tooth still infiltrates material, therefore not allowing hole to collapse when being stretched.Described additional stretching step not only makes hole become wider, and has the fibroreticulate probability producing and have corrugated outward appearance.This perforate must accurately be aimed at the combination of after-drawing.If perforate and stretching is carried out with independent process, as prior art, then hole will not aimed at stretch ring roller and hole may close.In addition, the fleece produced by this new technology is more soft and have more drapability (fiber of loose and/or thinning and/or film) due to stretching.Thinner fleece is generally desired, because described fleece can keep less fluid.When fleece is used as the top flat of absorbent article, this point is very important, because the saturation in top flat is less.

In one non-limiting embodiment, perforate web material comprises the fleece with the discrete holes be formed at wherein.This fleece has first surface and the second surface relative with first surface.This fleece comprises non-open area substantially around multiple discrete holes or matrix.

This some holes is deposited in relatively little region thick and fast.Such as, in any direction, the center to center spacing between hole can be less than or equal to about 20mm, 10mm, 5mm, 3mm, 2mm, 1mm, or 0.5mm.Area is 1 square inch of (645mm ²) region in the total number in hole can be more than or equal to 4,25,100,250,500,1000, or 3000.The number in the hole in one inch square region is determined by such as under type: on material, draw a square area being of a size of 1 inch (25.4mm) and taking advantage of 1 inch with apicule pen or marking pen, and to being completely or partially positioned at this 1 inch square or being positioned at its borderline first hole, second hole, the number in the 3rd hole etc. counts.If needed, low power microscope or other magnification assisting equipment can be used to carry out the visuality of auxiliary material mesopore.Hole can be any suitable configuration.

Hole can be any suitable size.Usually, hole by for macroscopic view.The plan view area in hole can be more than or equal to about 0.5mm ², 1mm ², 5mm ², 10mm ², or 15mm ².Method as herein described also can be used for producing microcosmic hole, and they have and are less than 0.5mm ²plan view area.

Except hole, fleece also can comprise ridge alternately and groove, and its mesopore is arranged in groove.Ridge extends serially or in the region of fibroreticulate distortion, forms discontinuous ridge.Groove extends serially, and the clearance gap of its mesopore with rule in groove is opened.It should be noted that if reversed by fleece, then groove will become ridge and ridge will become groove, and hole will be positioned at chi chung now.Depend on technique and material parameter, hole can be two dimension or three-dimensional.With regard to three-dimension hole, the base portion in hole extends on the rightabout of ridge.Portion compares with bottom portion of groove with crestal culmination, and ridge side and groove side are in orientation to a greater extent in a z-direction.

With regard to film, due to the cause of drawing process, ridge side and groove side and crestal culmination portion compare with bottom portion of groove can be thinner and have lower basic weight.This causes fleece to have the lower region in thickness alternately and the higher region of basic weight and thickness and basic weight, wherein thickness and the higher region of basic weight are arranged in crestal culmination portion and bottom portion of groove, and in the sidewall of the region with lower thickness and basic weight between them.Basic weight alternately provide the thinning benefiting comfort level/flexible region maintain the thickness benefiting intensity.

With regard to non-woven material, basic weight is reduced equally in stretch zones, this causes fleece to have the region that basic weight is higher and basic weight is lower alternately equally, and the region that wherein basic weight is higher is arranged in crestal culmination portion and bottom portion of groove, and in the sidewall of the lower region of basic weight between them.With regard to non-woven material, web thickness can not reduce in stretch zones, tangles because fiber can be removed and moves away from each other.But the thickness of some in each fiber described can reduce due to stretching, cause fibre diameter in 40% to 80% scope of initial fiber diameter.The fiber diameter at place of crestal culmination portion and the fiber diameter at bottom portion of groove place can be greater than the fiber diameter of side-walls.Although tooth is locked in ridge and groove, base portion web thickness does not change significantly.Although fleece is veining, the fibroreticulate thickness that local is positioned at ridge and groove does not change significantly, and this is because ridge and groove are not filled, but defines hollow region, because they have been deformed into outside plane.The ridge of hollow can not keep many fluids as the ridge of filling, and when being used as the top flat in absorbent article, it can provide dry and comfortable beneficial effect.Due to the cause stretched, fleece permanently extends in the stretching direction.Aptly, the web thickness in stretch zones is 20% to 80% of initial web thickness.

iI. for the equipment of the prior art that makes web material be out of shape

The method of prior art is not suitable for the hole that generation has wider size in the horizontal, especially for tough and tensile or tear resistance film.Therefore, wish to design following technique, with identical processing step (namely it make it possible to, in identical roll gap and during perforate tooth still penetrates fleece) to carry out perforate and stretch to obtain hole in web material, the hole that the method for described Kong Yuyong prior art can obtain is compared has large-size in the horizontal.The method of prior art is not suitable for use high speed perforate and all perforates as described here of stretching device and stretching device yet and produces the fleece with ridge alternately and groove, and its mesopore is arranged in groove.

Fig. 1 shows the equipment 10 of the first prior art, and its central roll 12 and 14 is called ring roller in this article.As when the roller in another equipment shown and described herein, roller 12,14 is carried on corresponding rotatable shaft, and rotatable shaft has the rotation axis A arranged with parallel relation.In all embodiments as herein described, roller is contactless, and is axially drive.In this embodiment, the surface of roller has the groove 16 and ridge 18 that circumferential extension multiple around roller replace.In other embodiments, the axis A that ridge and groove can be parallel to roller extends.This type of roller one or more can be used in the various embodiments of equipment described herein.

In the embodiment shown in Fig. 1 and other embodiment various as herein described, roller engages or engages each other at least in part.As shown in fig. 1, roller rotates (that is, roller is reversion) usually in the opposite direction.This is also like this for other embodiment as herein described.

Fig. 2 A – 2C shows the equipment 20 of the second prior art, and wherein apex roller 22 is hobboing cutter perforate (or " RKA ") roller, and lower roller 24 is called ring roller in this article.What this equipment comprised a pair reversion engages each other roller, wherein apex roller 22 comprises the pyramid tooth 30 with a four or more side, these sides are substantially leg-of-mutton and from base portion towards end convergent, and lower roller 24 comprises groove 26 and ridge 28 that circumference extends.Tooth 30 is arranged to isolated circumferential row, between described row, have groove.Tooth 30 extends from apex roller 22 at base portion place, and the base portion of tooth has the cross-section lengths size being greater than cross-section width dimension.Usually, when the tooth 30 on hobboing cutter perforate roller 22 engages each other with the groove 26 on ring roller 24, hole is formed in web material.About tooth depth, tooth pitch, pitch, the depth of engagement, and other process parameter, hobboing cutter perforate and hobboing cutter tapping equipment can identical with described in U.S. Patent Application Publication US 2006/0087053 A1.

Hobboing cutter perforate roller 22 shown in Fig. 2 A comprises staggered (vs. standard) tooth pattern.As used herein, term " staggered " refers to that adjacent teeth does not become row alignment in the horizontal.As used herein, term " standard " refers to that adjacent teeth becomes row alignment and in the horizontal therefore for noninterlace.As shown in Figure 2 C, roller 22 and 24 aligns in the horizontal, and the tooth 30 on hobboing cutter perforate roller 22 is alignd with the groove 26 on ring roller 24.When tooth 30 penetrates fleece, the spinal branches support fleece on pairing ring roller 28, makes tooth 30 can penetrate fleece and forms hole in the opposite direction simultaneously.Fig. 2 D shows the top view of the fleece 34 of exemplary prior art, and described fleece can be prepared by the equipment shown in similar Fig. 2 A – 2C.The fleece 34 of gained comprises the matrix 36 of surrounding hole 38.The hole 38 formed by the equipment of the equipment of prior art similar Fig. 2 A – 2C comprises the length L longitudinally and width W transversely.This some holes normally slit sample, has the width W being far smaller than length L, especially for more tough and tensile and have more restorative fleece.

iII. the tooth having and extend from convex ridge is utilized web material to be carried out to equipment and the method for perforate

In general, this equipment is included in two the intermeshing shaped structures forming roll gap between the two.Shaped structure can comprise roller, plate, band, sleeve pipe, can to fleece give texture to other structure or their combination.First shaped structure comprises multiple first ridge on the surface of shaped structure and the first groove, and wherein said first ridge has top surface, and described first groove has lower surface.First shaped structure also comprises from the outward extending isolated multiple tooth of the top surface of described first ridge, and each tooth all can form hole, and the top surface of wherein said first ridge is between the end and the lower surface of described first groove of described tooth.Second shaped structure comprises multiple continuous print second ridge and the second groove.

More specifically, what this equipment was included in single a pair reversion forming single nip N between the two engages each other roller.Although for simplicity, mainly will describe these equipment with roller herein, should be appreciated that any suitable equipment of formed parts that this description will be applicable to comprise any suitable type, described formed parts includes but not limited to: pair of rolls; Multipair plate; There is the transporter of puck (or platelet); Band; Or their combination.First roller and the second roller comprise surface 106,108 separately, and described surface comprises multiple ridge and the groove of circumference extension.Alternatively, ridge and groove can extend on the direction being parallel to roll axis, as long as itself and the roller having the ridge that extends in the same direction and groove and match.First roller also comprises isolated multiple tooth in addition, and wherein tooth stretches out from the top surface of ridge.This produces " convex ridge ".The ridge of the second roller is towards the Axis Extension of the first roller to the degree of depth at the top of at least some more than the chi chung on the first roller.Like this, the initial engagement of tooth produces hole, subsequently when described be engaged into the degree of depth walking to below convex ridge time, described hole is stretched in the horizontal.Stretch during tooth still penetrates fleece subsequently by first carrying out perforate in a processing step, the hole of gained with by the standard discaling roll as mentioned above and as shown in Fig. 2 A – 2D there is larger width in the horizontal compared with the hole that produces.

Hole of the present invention comprises lower aspect ratio (hole length: hole width) and much higher aperture area compared with the hole of prior art, especially when for more tough and tensile film, such as, comprises those of the LLDPE of high-load.New tooth geometry is conducive to obtaining high aperture area under lower mold temperature, makes it possible to form hole in fleece, and described fleece can not by perforate for having conventional tooth geometry.Under new die geometry is provided in lower temperature (such as, between 35 and 70 degrees Celsius) or even at ambient temperature to the ability of fleece perforate, and do not need to heat equipment.In addition, relative to former mould, involved is few or lower in order to the cost producing this mould, because the metal be especially removed is less.Therefore, room temperature precursor web can be used.In one embodiment, precursor web and engage each other roller and be not heated.Maybe can use the fleece of overall preheating.Or subregion preheating fleece can make it possible to form hole and form bubble in some districts in other district.Preheating realizes by following method: wrap up hobboing cutter perforate roller (wherein may use the parcel time of change before splicing) before splicing or wrap up ring roller before splicing.Equally, that be heated or the non-mould be heated can be used.Aptly, be heated to 50-200 degree Celsius by parcel, or the hobboing cutter perforate roller of 50-100 degree Celsius heats fleece.Hobboing cutter perforate roller can be driven by the speed of identical outmost surface with ring roller, or can there is speed difference between described two rollers.

The following non-limitative example illustrating the perforate web material that particular roll arranges and can be formed thus.These equipment can utilize single roll gap, and run with higher position reason speed, in some cases without the need to heating, and to compare with the method for the prior art of stretching spend less (such as, because it is simple mechanical technology-only have two to engage each other roller) with for carrying out perforate.

Fig. 3 A and 3B shows example devices 100 of the present invention, and what it was included in single a pair reversion forming single nip N between the two engages each other roller 102,104.The modification that first (top) roller 102 is the roller of hobboing cutter perforate shown in Fig. 2 A.This particular variant will be called in this article " convex ridge hobboing cutter perforate roller ".In equipment 100 shown in Fig. 3 A and 3B second (bottom) roller 104 is ring roller.

As shown in Figure 4 A, the first roller 102 comprises multiple groove 110 and ridge 120, and from the outward extending multiple staggered isolated tooth 130 of the top surface 122 of ridge 120.The configuration of roller 104 makes the top surface 122 of ridge 120 be arranged between the end 134 of tooth 130 and the lower surface 112 of groove 110, determines according to the direction relative to the axis A of roller.As shown in Figure 4 B, the second roller 104 comprises multiple groove 140 and ridge 150.Groove 140 has lower surface 142, and ridge 150 has top surface 152.Herein, the distance between the top surface 152 of ridge 150 and the lower surface 142 of groove 140 is substantially the same around the circumference of this roller.Fig. 4 C is alternative second roller 104B of the transversary elastic-like film roll form of interlocking in convex ridge.The configuration of roller 104B makes the top surface 122 of ridge 120 be arranged between the end 134 of tooth 130 and the lower surface 112 of groove 110, determines according to the direction relative to the axis A of roller.Again with reference to figure 3A and 3B, the tooth 130 of the first roller 102 and ridge 120 extend towards the axis A of the second roller 104, engage each other the degree of depth to the top 152 more than at least some in the ridge 150 on the second roller 104.

The tooth being applicable to this technique must be conducive to carrying out perforate to fleece.Tooth on roller can have any suitable configuration.Given tooth can have identical plane graph length and width dimensions (such as having the tooth of circle or square-shaped planar figure).Alternatively, tooth can have the length (such as having the tooth of rectangle plane figure) being greater than its width, and in this case, tooth can have any suitable aspect ratio of its length and its width.Suitable configuration for tooth includes but not limited to: the tooth with triangle side view; There is the tooth of square or rectangular side view; Columnar tooth; Pyramid tooth; Have and comprise circle, oval, hourglass shape, star, the tooth of the plane graph configuration of polygon etc.; And their combination.Polygon includes but not limited to rectangle, triangle, pentagon, hexagon or trapezoidal.The sidewall of tooth can from base portion to end with constant angle convergent, or their changeable angles.Tooth can towards the single point convergent of tooth end, than tooth as shown in Figure 4 A.Tooth can have end that is sphering, smooth or that taper off to a point.Alternatively, tooth can towards multiple spot, and the tooth end convergent of elongation, than structuring elastic-like film tooth as shown in Figure 4 C.But the end of tooth must one of at least (such as, the vertical wall on the front-end and back-end of tooth, forms pinnacle as shown in Figure 4 C), and therefore tooth is to fleece perforate or pierce through fleece with the vertical wall of tooth.With regard to the tooth shown in Fig. 4 C, each tooth can form 2 holes, a leading edge being positioned at each tooth, and another is positioned at trailing edge.

In the exemplary embodiment of shown in Fig. 5 A-F, the first roller 102 comprises from the outward extending multiple pyramid tooth 130 of the top surface 122 of ridge 120.Fig. 5 A is the perspective view of the part on the surface of another exemplary convex ridge hobboing cutter perforate roller.Fig. 5 B for the side view of the gear mutation shown in Fig. 5 A, Fig. 5 C be end-view, and Fig. 5 D is top view.The profile of Fig. 5 E for intercepting along the line D-D of the gear mutation shown in Fig. 5 B.The profile of Fig. 5 F for intercepting along the line E-E of the gear mutation shown in Fig. 5 B.Tooth cross-sectional area A shown in Fig. 5 E _tbe less than the tooth cross-sectional area A shown in Fig. 5 F _tb.Side (the 130a – 130f such as, shown in Fig. 5 E) is substantially leg-of-mutton and from end 134 to base portion 132 with constant angle convergent.The number of side can be four (such as, Fig. 4 A), six (such as, Fig. 5 A – 6C), or for being less than or equal to another number of 12.Tooth 130 is arranged to isolated circumferential row, has groove 110 between described row.Longitudinal end is to terminal teeth apart from S _mDfor 0.4mm to 15mm (or 3mm to 8mm).Transverse pitch P is 0.4mm to 10mm (or 1mm to 3mm).Tooth has the angle α of 30 to 90 degree (or 45 to 65 degree), the long side surface of the tooth of 3 to 15 degree (such as, 130c, 130f) on side wall angle β, and 45 to 120 degree (or 60 to 90 degree) the leading edge of tooth and the end facet angle γ (angle such as, between 130a and 130b of side or the angle between 130d and 130e of side) of trailing edge.In some cases, when producing tooth by helical form grinding, selecting staggered and comprising the vertical and horizontal tooth pitch of end facet angle γ.

There is the different modes in order to the finishing wherein part 136 of tooth 130 and ridge surface 122 intersection, such as, truncation (Fig. 6 A), the convergent portion wherein on each side is all clipped by certain plane; (Fig. 6 B) of half truncation, the convergent portion wherein at least one side is clipped by certain arc; Or (Fig. 6 C) of non-truncation, the convergent portion wherein on each side is clipped never in any form.Tooth 130 shown in Fig. 6 A is from end 134 towards base portion 132 convergent and have the bottom 136 of truncation.Convergent and/or truncation can be carried out by the different number of degrees.The convergent portion of the truncation on tooth makes dental transition be easy to manufacture.In this case, see Fig. 7, as known by shaping in operation, in single helical form machining steps, realize end facet angle γ and ridge finishing by following method: at circumferential D _cupper rotary die, processes at the axially pusher of mould simultaneously.Along machined path M _pthe end facet of tooth 130 will be produced.Tooth is interlocked portion T _s, therefore included end facet angle γ is generated as 2*Arctan, and (transverse teeth pitch " P "/tooth interlocks portion " T _s").

Differently can carry out the top surface 122 of the ridge between finishing tooth 130.Such as, surface 122 can be radioactive or non-radiative formula.Protection fleece is not torn, especially with regard to film by radioactive surface between Formation period; But not radioactive surface (such as the surface 122 shown in Fig. 6 A – 6C) more can save cost.

The configuration of convex ridge hobboing cutter perforate roller 102 makes the top surface 122 of ridge 120 be arranged between the end 134 of tooth 130 and the lower surface 112 of groove 110, determines according to the direction relative to the axis A of roller 102.Tooth depth h _tbe defined as the distance between the end 134 of tooth 130 and the lower surface 112 of groove 110.Tooth depth h _tfor 1mm to 12mm, or 2mm to 8mm, or 3mm to 6mm.Ridge height h _rfor at least 20% of tooth depth, be generally 20% to 95%.Crosscut degree of depth d _ccbe defined as the distance between the end 134 of tooth 130 and the top surface 122 of ridge 120.In this embodiment, the distance between the end 134 of tooth 130 and the top surface 122 of ridge 120 is substantially the same around the circumference of this roller.Crosscut degree of depth d _ccdepend on the deflection formed needed for described hole.Such as, crosscut degree of depth d _cccan at 0.2mm to 9mm, or in 1.0mm to 4.0mm or 2.0mm to 3.5mm scope.Less crosscut degree of depth d _cc(under identical DOE) produces the hole of more big uncork.Pair of rolls 102, the depth of engagement of 104 must be greater than crosscut degree of depth d _cc.Aptly, the depth of engagement is than the large at least 0.1mm of the crosscut degree of depth or large 0.3mm.The DOE at nip N place is 0.5mm to 10mm, or 3mm to 7mm, or 3mm to 4mm.

Ridge height h _rbe defined as the distance between the top surface 122 of ridge 120 and the lower surface 112 of groove 110.In some the such as embodiment shown in Fig. 3 B and 4A, first roller 102 comprises transverse width, and the distance between the top surface 122 of ridge 120 and the lower surface 112 of groove 110 is substantially the same around described circumference and across the transverse width of roller 102.Or first ridge top surface and the lower surface of the second groove between distance can change around described circumference or across the transverse width of the first roller.Various alternative embodiment of convex ridge roller is possible.Such as, as shown in the roller 162 in Fig. 8, the height h of ridge _rcan change between at least some in tooth 168.Ridge height h _rdepend on the deflection needed for the hole desired by formation.The top surface 166 of at least one ridge 164 between a pair tooth 168 will have following height h _r1, described height is by least 10%, 20%, or 30% is greater than at another height h to another ridge 164 between tooth 168 _r2.This roller 162 can be used for all technique as shown in Figure 3A of certain technique to replace convex ridge hobboing cutter perforate roller 102.Second roller can be ring roller, and it has at circumference or the ridge axially with differing heights.

Fig. 9 A shows an example of the fleece 170 prepared by the equipment shown in Fig. 3 A: the hobboing cutter perforate convex ridge roller with staggered tooth pattern is used as top roll 102 and ring roller and is used as lower roll 104.Roller 102 and 104 aligns in the horizontal, and the tooth 130 on the first roller 102 is alignd with the groove 140 on the second roller 104.When the tooth 130 on the first roller 102 penetrates fleece 170, the ridge 120 between the tooth 130 on hobboing cutter perforate convex ridge roller 102 supports fleece 170, makes ridge 150 on the second roller 104 can drawing of fiber net 170 in the horizontal.

The fleece being in its original state can be considered to relatively flat, and is made up of non-open area completely.Fleece 170 has first surface 170A and second surface 170B.When fleece is fed in the nip N be positioned between roller (such as, shown in Fig. 3 A those) in the vertical, fleece: (i) by tooth 130 perforate of the first roller 102 to form isolated multiple hole 172; And (ii) stretched by the ridge 120 of the first roller 102 with stretchable holes 172 in the horizontal.As shown in Fig. 9 A and fleece top view, result obtains the perforate fleece 170 of the matrix 174 comprising hole 172 and surrounding hole 172.Hole 172 can (down, as observed in figure 9 a) be pushed out outside the plane of fleece 160 in one direction, and therefore hole 172 can have height H _a.Hole 172 becomes row alignment in machine and transverse direction.Fig. 9 B shows the amplification vertical view in single hole 172.Hole 172 comprises the length L longitudinally _awidth W transversely _a.Hole will preferably have length divided by 1 to 4 of width, or 1.25 to 3, or 1.5 to 2.5, or the aspect ratio AR of 1.6 to 2.3.Hole 172 also comprises each aperture area A _awith around aperture area P _aperiphery.Total aperture area included by perforate fleece is 5% to 25% of total fiber web area, or 9% to 21%, or 10% to 16%, or 14% to 20%.Apertured film is included in 1.5N to 5N, 2N to 4N, 2.5N to 4N, 2.5N to 3.5N, or the tearing or hot strength (every 25.4mm) transversely in 2.7N to 3.9N scope.Apertured nonwovens comprises in 2N to 20N scope, or higher hot strength (every 25.4mm) transversely.In one example in which, fleece comprises machine-direction oriented and horizontal orientation, and its mesopore comprises the length longitudinally and width transversely, and wherein multiple hole comprise length divided by width 1 to 4 aspect ratio.

In certain embodiments, above-mentioned stretching step not only increases the transverse width in hole, and creates ridge alternately and groove, and its mesopore is arranged in groove.The fibroreticulate partial frictional contacted with the ridge on described two rollers is locked in crestal culmination portion and is not thus stretched, and the fleece between ridge is stretched outside out-of-plane.The fibroreticulate part be stretched outside out-of-plane becomes in orientation to a greater extent in a z-direction.Therefore, can form the fleece with ridge and groove, its mesopore is arranged in groove.It should be noted that if reversed by fleece, then groove will become ridge and ridge will become groove, and hole will be positioned at chi chung now.The fiber at place of crestal culmination portion and the fiber at bottom portion of groove place can be oriented in X-Y plane to a greater extent compared with the fiber of side-walls.

With regard to film, in stretch zones fleece by thinning and basic weight reduce, and web thickness and basic weight remain unchanged in the fibroreticulate region of friction lock on hump.This causes fleece to have the region that thickness is alternately higher and thickness is lower and the region that basic weight is higher and basic weight is lower replaced, the region that wherein higher the and basic weight of thickness is higher is arranged in crestal culmination portion and bottom portion of groove, and in the sidewall of the region with lower thickness and lower basic weight between them.Figure 11 is the top view (film be stretched/flattened to illustrate high basis weight regions 212 and low basis weight regions 214) of 25gsm PE membrane fiber net 210.Fleece 210 also show ridge R, groove G, and sidewall S.Hole 216 is present in groove G.Obviously, high basis weight regions 212 is arranged in ridge R and groove G, and low basis weight regions 214 is arranged in sidewall S.

With regard to non-woven material, basic weight is reduced equally in stretch zones, this causes fleece to have the region of higher basis weights alternately and lower basic weight equally, and wherein higher basis weights region is arranged in crestal culmination portion and bottom portion of groove, and in the sidewall of lower basis weight regions between them.Figure 12 is the top view (non-woven material be stretched/flattened to illustrate high basis weight regions 222 and low basis weight regions 224) of 60gsm polypropylene nonwoven fleece 220.Fleece 220 also show ridge R, groove G, and sidewall S.Hole 226 is present in groove G.Thermal bond points or fusion bounding point 228 can be present in the various positions on fleece 220.Obviously, high basis weight regions 222 is arranged in ridge R and groove G, and low basis weight regions 224 is arranged in sidewall S.With regard to non-woven material, web thickness can not reduce in stretch zones, tangles because fiber can be removed and moves away from each other.But the thickness of some in each fiber described can reduce due to stretching.It should be noted that fibroreticulate " region " for characterizing basic weight does not comprise hole self.

Due to the cause stretched, fleece permanently extends in the stretching direction.If fleece remains on its corrugated state, then the major part of increased web width is formed on ridge in fleece and groove is filled.Alternatively, can apply tension force to stretch fleece, the height and frequency that cause ridge and groove reduce by this, and reduce fibroreticulate overall basis weight.If needed, extendable fiber net makes ridge and groove no longer exist, and fleece returns back to its flat.This deformation technique can in the horizontal drawing of fiber net or make fleece grow 10%, 15%, 20%, 25%, or more.The permanent elongation amount of ridge and groove and forming degree depend on mould geometry, process conditions and properties of materials.Usually, compared with membrane material, this technique will permanently draw nonwoven web material or nonwoven fibrous web material is grown more.Such as, fleece can grow to 190mm from 165mm in the horizontal.Aptly, this fleece has initial web basis weight regions and lower basis weight regions, and described lower basis weight regions has the basic weight lower than initial web basic weight.

Figure 13 is the cross-sectional view of fleece 220 shown in Figure 12, shows ridge, groove G, and flatly through axis X that fibroreticulate cross section draws; To be positioned at above X-axis line but the region be positioned at below crestal culmination portion is hollow, or to comprise the region HA of hollow.Equally, to be positioned at below X-axis line but the region be positioned at above bottom portion of groove is hollow, or to comprise the region HA of hollow.Aptly, the web thickness at place of crestal culmination portion and the web thickness at bottom portion of groove place are similar.The web thickness at place of crestal culmination portion and the web thickness at bottom portion of groove place can be similar to the web thickness of side-walls.So-called similar, refer to that thickness is within about 60% each other.Or the web thickness at the web thickness at place of crestal culmination portion and bottom portion of groove place is greater than the web thickness of side-walls.Figure 14 is the side perspective view of another non-woven webs 230 with ridge 232, groove 234 and sidewall 236.Figure 15 is the top perspective of 28gsm polyethylene/polypropylene bicomponent nonwoven fleece 240, and described non-woven webs comprises ridge 242 and groove 244 and hole 246, wherein hole width W _abe greater than ridge width W _r.Figure 16 is the profile of membrane fiber net 250, it illustrates the thinning that the bottom place of the top of the ratio ridge 252 at sidewall 256 place or groove 254 is larger.

Technique herein also can utilize multiple deforming step more gently to make material deformation or to give larger set deformation volume.This type of multiple deforming step by authorize the people such as Lake U.S. Patent Application Serial Number 13/094,195 described in any suitable equipment carry out.Aptly, at least the first roller or the second roller also form roll gap with one or more additional rollers thus further drawing of fiber net or fleece is out of shape.In one arrangement 200 as shown in Figure 10, ring roller 202 and convex ridge roller 204 match, and described convex ridge roller matches with another ring roller 206 then, makes these rollers be in planetary or satellite-type configuration.Also can carry out utilizing the technique of multiple deforming step on following equipment to carry out desired distortion: there is the nested type equipment of relatively small number object roller being in nested type arrangement, or such as have any suitable number roller mixing, closed loop and the equipment of the row of sharing and so on.

Numerous alternative embodiment of perforate web material and preparation technology thereof is possible.Such as, can provide following web material, they have different district'ss (comprising deformed area and/or non-deformed area) across the surface taken on a different character.These districts can be selected from by least one feature: ridge is high, ridge spacing, hole dimension, fibre diameter, film thickness, or their combination.In one embodiment, can provide following perforate web material, it has porose area, and has ridge district and groove area in some cases.Fleece disclosed herein can comprise ridge district and the groove area of hole and/or different size and the frequency with different size.Fleece can comprise one or more layer.In another embodiment, described film is the microtexture film comprising stretch zones and non-stretch zones, and wherein stretch zones has the microtexture characteristic being different from non-stretch zones, and wherein microtexture characteristic is selected from aperture area, size, orientation, and their combination.The fleece prepared by method and apparatus as herein described can comprise the ridge extended discontinuously across deformed area, or across the ridge that deformed area extends continuously.In order to produce this type of perforate web material, ring roller used can comprise ridge district and groove area.Or ring roller can have the district that its median ridge is differing heights, thus the degree of depth and therefore there is the hole of different width and aperture area under producing the different depth of engagement (DOE), different convex ridge.Alternatively or in addition, convex ridge roller also can comprise different districts, its median ridge is high is different in different districts.

example

example 1

One in polymeric film, prepare hole limiting examples than in fleece 300 (comprising microcosmic hole 312 and macroscopic pores 314) as shown in figure 17, the equipment comprised with the convex ridge hobboing cutter perforate roller of the intermeshing 1.5mm pitch of ring roller of the 3.8mm depth of engagement and 1.5mm pitch can be used.Convex ridge hobboing cutter perforate roller has the tooth being oriented to and length direction is extended in the vertical.These teeth are arranged to the pattern interlocked, as shown in Figure 5A.These teeth have the pyramidal shape of 6 sides with the most advanced and sophisticated convergent from base portion to end, and have the height h of 4.7mm _t.These teeth have the angle (α in Fig. 5 B) of 62 degree, the side wall angle (β in Fig. 5 C) on the long side surface of the tooth of about 6 degree, and the end facet angle (γ in Fig. 5 E) of 90 degree.The ridge crossed between tooth on hobboing cutter perforate roller be non-radiative formula and form flat surfaces.These teeth sentence half truncation pattern by finishing at ridge, as shown in Figure 6B.Ridge and groove extend around ring roller circumference.

The tooth section that existence two kinds is different on roller, they are demonstrated out with the beneficial effect showing convex ridge and are individually called " section A " and " section B ".Section A has the longitudinal tooth pitch S of end to the 4.9mm of end _mD, the crosscut degree of depth (d in Fig. 6 A of 3.6mm _cc) and the high (h in Fig. 6 A of gained ridge of 1.1mm _r).Section B has the longitudinal tooth pitch S of end to the 3.7mm of end _mD, the crosscut degree of depth d of 2.7mm _cc, and the gained ridge height h of 2.0mm _r.

Pairing ring roller is the pitch of 1.5mm, has the height of 4.8mm, the tip radius of 0.12mm, and the side wall angle of about 4 degree.These two rollers all have the diameter of about 205mm, and are heated to 80 degrees Celsius.Hobboing cutter perforate roller and ring roller align in the horizontal and make the gap on the bilateral of tooth approximately equal.

Precursor web is microcosmic open cell polymer film, and its basic weight is 26g/m ², there is the blend of LLDPE and LDPE, can purchased from RKW-Group (Germany).LLDPE comprises the film composition of about 60%, the LDPE of about 30%, and remaining 10% is inert substance and filler such as TiO ₂with its vector resin.Microcosmic hole is 55 orders (number of pores per inch on orthogonal direction), and they are arranged to equilateral triangle pattern, and wherein center to center spacing is about 462 microns.Bore dia is 175-200 micron, and the cone height of convergent is about 120 microns.

With the linear fibre net spee of 480 ms/min before engaging each other and passing between roller, by precursor web pre-wrapped on ring roller.The microcosmic perforate cone flank face of film is placed to towards hobboing cutter perforate roller.Use the depth of engagement of 3.8mm.The film of gained is illustrated in Figure 18 A and 18B with low amplification.Aperture area (there is the percentage ratio of the membrane area in the hole of opening), hole length, measure with the hole width visual system of described film, all if with the visual system of IN-SIGHT trade name purchased from Cognex Corporation (Natik, Massachusetts).Hole (Figure 18 A) from section A is illustrated in following table with the comparative result of aperture area, length and the width in the hole (Figure 18 B) from section B.Figure 18 A and 18B shows membrane fiber net 320,340, and they have microcosmic hole 322,342 and hole 324,344.

example 2

Can use following equipment at one for the preparation of having in the limiting examples of corrugated web in hole in a groove, described equipment comprises with the convex ridge hobboing cutter perforate roller of the intermeshing 2.0mm pitch of ring roller of the 6.3mm depth of engagement and 2.0mm pitch.Convex ridge hobboing cutter perforate roller has the tooth being oriented to and length direction is extended in the vertical, and ridge and groove extend around ring roller circumference.Tooth is arranged to the pattern interlocked, as shown in Figure 5A.These teeth have the pyramidal shape of 4 sides with the most advanced and sophisticated convergent from base portion to end, and have the height h of 6.9mm _t.These teeth have the side wall angle (β in Fig. 5 C) on the long side surface of the angle (α in Fig. 5 B) of 57 degree and the tooth of about 5 degree.The ridge crossed between tooth on hobboing cutter perforate roller is not sphering and forms flat surfaces.These teeth sentence non-truncation pattern by finishing at ridge, as shown in Figure 6 C.These teeth have the longitudinal tooth pitch S of end to the 8.0mm of end _mD, 3.7mm the crosscut degree of depth (d in Fig. 6 A _cc) and the high (h in Fig. 6 A of gained ridge of 3.2mm _r).

Pairing ring roller is the pitch of 2.0mm, has the height of 6.9mm, the tip radius of 0.12mm, and the side wall angle of about 4 degree.These two rollers all have the diameter of about 142mm.Hobboing cutter perforate roller and ring roller align in the horizontal, make the gap on arbitrary side of tooth approximately equal.

First precursor web is polymeric film, and its basic weight is 25g/m2, has the blend of LLDPE and LDPE, can purchased from Clopay Plastics Co. (Ohio).Before passing between intermeshing roller with the linear fibre net spee of 20 ms/min, by precursor web pre-wrapped on ring roller.The corrugated apertured film of gained is illustrated in Figure 11 (film be stretched/flattened to illustrate high basis weight regions and low basis weight regions).Use optical microscope all if the optical microscope purchased from Allasso Industries obtains image with low amplification, optical microscope uses red LED back lighting.

Second precursor web is the polypropylene nonwoven of hot adhesion, and its basic weight is 60g/m2, can purchased from Fiberweb (France).Before passing between intermeshing roller with the linear fibre net spee of 20 ms/min, by precursor web pre-wrapped on ring roller.The corrugated apertured nonwovens of gained is illustrated in Figure 12 (top view; Fleece is stretched/flattened to illustrate high basis weight regions and low basis weight regions), in Figure 13 (cross-sectional view), Figure 19 A (convex ridge hobboing cutter aperture side) and Figure 19 B (ring roller side).Use all if the optical microscope purchased from Allasso Industries obtains image with low amplification.Fleece 400 in Figure 19 A and 19B comprises ridge 402 alternately and groove 404; Hole 406 is present in groove 404.

Size disclosed herein and numerical value should not be understood to be strictly limited to described exact numerical values recited.On the contrary, except as otherwise noted, each above-mentioned size is intended to represent the function equivalent scope near described value and this value.Such as, the size being disclosed as " 40mm " is intended to represent " about 40mm ".In addition, the numerical range quoted herein comprises and is in each discrete numerical value within the scope of this and other comparatively close limit any.Should be appreciated that each higher limit provided in this manual comprises each lower limit, also clearly represented in this article as this lower limit.Each the minimum value limit provided in this specification will comprise each high value limit, clearly be represented in this article as this high value limit.Each numerical range provided in whole description will comprise each the narrower numerical range fallen in this type of wider numerical range, and just such a narrower numerical range is write out clearly equally in this article.

The All Files quoted in detailed Description Of The Invention is all incorporated herein by reference in relevant portion.The quoting of any document may not be interpreted as its accreditation as prior art of the present invention.If in this written document any implication of term or definition and term described in introducing file for reference any implication or define inconsistent, be then as the criterion with the implication or definition of giving described term in this written document.

Although illustrate and describe the present invention with specific embodiment, it is obvious for those of skill in the art that, can make when not deviating from the spirit and scope of the present invention many other change and amendment.Therefore, all these being intended to contain in the scope of the invention of following claims change and modification.

Claims (15)

1. an equipment, described equipment comprises two intermeshing reverse rolls, and described two intermeshing reverse rolls form roll gap between the two, and described equipment comprises:

A) the first roller of general cylindrical, described first roller has surface, circumference and axis, and described first roller comprises:

Multiple circumferential first ridge on the surface of described roller and circumferential first groove, wherein said first ridge has top surface, and described first groove has lower surface; With

Isolated multiple tooth, described tooth stretches out from the top surface of described first ridge, and each tooth is all from described top surface to end convergent, and the top surface of wherein said first ridge is between the end and the lower surface of described first groove of described tooth; With

B) the second roller of general cylindrical, described second roller comprises multiple continuous print circumference the second ridge and circumferential second groove.

2. equipment according to claim 1, wherein said first roller comprises the crosscut degree of depth that the described end from the top surface of described first ridge to tooth is measured, wherein said roll gap comprises the depth of engagement between described first roller and described second roller, and the wherein said depth of engagement is greater than the described crosscut degree of depth, the preferably wherein said depth of engagement at least 0.1mm larger than the described crosscut degree of depth.

3. according to equipment according to claim 1 or claim 2, wherein said roll gap comprises the depth of engagement between described first roller and described second roller, and the wherein said depth of engagement is 3mm to 4mm.

4. according to equipment in any one of the preceding claims wherein, wherein said first roller comprises transverse width, and wherein around described circumference and across the transverse width of described first roller, the distance between the top surface of described first ridge and the lower surface of described first groove is substantially the same.

5. the equipment according to any one of claim 1-3, described first roller comprises transverse width, and wherein around described circumference or the transverse width across described first roller, the distance between the top surface of described first ridge and the lower surface of described first groove changes.

6. according to equipment in any one of the preceding claims wherein, wherein said tooth be faceted and comprise at least four or six sides.

7., according to equipment in any one of the preceding claims wherein, the part of wherein said tooth and the intersection of ridge surface institute is finishing, with provide be selected from truncation, half truncation, non-truncation and their geometry of combination.

8., according to equipment in any one of the preceding claims wherein, wherein said first ridge has height, and wherein said height is at least 20% of the height of described tooth.

9. according to equipment in any one of the preceding claims wherein, the top surface of wherein said first ridge is selected from radioactive, non-radiative formula or their combination.

10., according to equipment in any one of the preceding claims wherein, wherein said second roller is the ring roller with ridge, and described ridge is in described circumference or axially have different height.

11. 1 kinds of methods for making fleece be out of shape, described method comprises feeds in roll gap by precursor web, and described roll gap is formed between two intermeshing rollers, and described two intermeshing rollers comprise:

A) the first roller of general cylindrical, described first roller has surface, circumference and axis, and described first roller comprises:

1) multiple first ridge and the first groove, described first ridge and the first groove extend on the surface of described roller around the circumference of described roller, and wherein said first ridge has top surface, and described first groove has lower surface; With

2) isolated multiple tooth, described tooth stretches out from the top surface of described first ridge, and described tooth has end, and the top surface of wherein said first ridge is arranged between the end of described tooth and the lower surface of described first groove; With

B) the second roller of general cylindrical, described second roller comprises multiple continuous print circumferential ridge and circumferential recess, and wherein said second ridge has top surface, and described second groove has lower surface;

Wherein when described fleece is fed in described roll gap, the top of at least some of the chi chung on described first roller extends inwardly to the degree of depth at the top of at least some of the second chi chung exceeded on described second roller towards the axis of described second roller, and described fleece: (i) by described tooth in isolated multiple primary importance perforate to form isolated multiple hole; And (ii) stretched in the cross direction by described intermeshing roller.

12. techniques according to claim 15, wherein at least described first roller or described second roller also form roll gap with one or more additional rollers thus the described fleece or make it be out of shape of stretching further.

13. techniques according to claim 15, wherein said precursor web and intermeshing roller are not heated.

14. techniques according to claim 15, wherein lead to described precursor web around being heated to the roller of 50-200 degree Celsius to heat described precursor web.

15. 1 kinds of fleeces, described fleece is prepared by according to equipment in any one of the preceding claims wherein or technique, and wherein said fleece preferably includes non-woven material; Lamilated body; Be selected from the film of LLDPE, LDPE, HDPE; Or their combination.