CN1176616A - 薄片材料穿孔方法 - Google Patents

薄片材料穿孔方法 Download PDF

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Publication number
CN1176616A
CN1176616A CN95196019A CN95196019A CN1176616A CN 1176616 A CN1176616 A CN 1176616A CN 95196019 A CN95196019 A CN 95196019A CN 95196019 A CN95196019 A CN 95196019A CN 1176616 A CN1176616 A CN 1176616A
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CN
China
Prior art keywords
sheeting
binding agent
pattern
liner
aperture
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN95196019A
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English (en)
Inventor
兰迪·A·霍夫
约翰·W·卢基斯
理查德·L·雅各布森
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Co
Original Assignee
Minnesota Mining and Manufacturing Co
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Filing date
Publication date
Application filed by Minnesota Mining and Manufacturing Co filed Critical Minnesota Mining and Manufacturing Co
Publication of CN1176616A publication Critical patent/CN1176616A/zh
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/24—Perforating by needles or pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/08—Means for treating work or cutting member to facilitate cutting
    • B26D7/086—Means for treating work or cutting member to facilitate cutting by vibrating, e.g. ultrasonically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
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    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
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    • B29C66/83411—Roller, cylinder or drum types
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2791/004—Shaping under special conditions
    • B29C2791/008—Using vibrations during moulding
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2793/0045—Perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2793/0054—Shaping techniques involving a cutting or machining operation partially cutting through the material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • Y10T156/1056—Perforating lamina
    • Y10T156/1057—Subsequent to assembly of laminae
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1082—Partial cutting bonded sandwich [e.g., grooving or incising]

Abstract

一种在薄片材料(14)上形成大于0.05平方毫米小孔的方法。该薄片材料具有第一面和第二面,该薄片材料的至少一面涂敷着粘结剂(116)。该方法包括以下步骤:(1)将涂敷粘结剂的薄片材料置于一具有由凸出表面构成的图案的图案砧筒(32)上;以及(2)使薄片材料经受足够量的声波振动,以便在薄片材料和粘结剂上穿孔;在薄片材料和粘结剂上钻出的小孔呈现出与图案砧筒(32)上的凸出表面构成的图案相同的图案。

Description

薄片材料穿孔方法
                     本发明的技术领域
本发明涉及以均匀图案在薄片材料上穿孔的方法。
                     本发明的技术背景
超声学基本上是关于在可听频率范围之外的声音振动效果的科学。使用大功率超声波的目的是给被加工的材料提供某些永久性的物理变化。这种加工需要在每单位面积或体积上提供振动能量流。根据用途，产生的能量密度可在从小于每平方厘米1瓦特到几千瓦特的范围里。虽然原来的超声波能量装置在射频范围内工作，但今天大多数在20-69kHZ范围内工作。
超声波具有广泛的用途。例如，超声波可用于(1)灰尘、烟雾和油雾沉淀；(2)胶状分散物的制备；(3)金属零件和织物的清洗；(4)摩擦焊接；(5)催化剂的形成；(6)熔融金属的除气和凝固；(7)酿造时香味油的抽取；(8)电镀；(9)对硬质材料穿孔；(10)无焊药焊接和(11)诸如特效药的非破坏性测试。
超声波振动力已被用于焊接织物材料的领域。授予奥贝特的第3,697,357号美国专利公布了完全地或部分地由热塑性材料或纤维制成的焊接片料。奥贝特公布了密封一部分材料的方法，即将它们置于一砧座和一超声波工作头之间。授予格尔加奇的第3,939,033号美国专利公布了一种超声波装置，以便同时密封和切割热塑性织物材料。授予顾特的第5,061,331号美国专利公布了另一种超声波切割和封边的装置，它适合于切割和密封半渗透性的并至少部分热塑性的织物。
超声波振动力还被用来对片状材料穿孔或穿孔。授予米切尔等人的第3,966,519号美国专利公布了一种对无纺卷料穿孔的方法。米切尔指出，提供给无纺卷料的超声波能量的大小可进行控制，即通过提供足够的流体给超声波能量作用在无纺卷料的地方，从而使流体以游离的形式存在。米切尔指出，无纺卷料的纤维可重新排列，从而在卷料上形成小孔。
授予奥斯特迈尔的第3,949,127号美国专利公布了一种对无纺卷料穿孔的方法，即给卷料提供间歇的超声波融化，然后拉伸卷料以便弄断融化最强烈的各区域，从而在卷料上形成穿孔。
超声波力还被用来在无孔的薄膜材料上穿孔。授予詹姆森等人的第5,269,981号美国专利公布了一种在薄片材料上钻微孔的方法，它需要在薄膜材料经受超声波振动前给薄膜材料涂敷液体。詹姆森还指出，在加工时包含液体是必不可少的。詹姆森指出，没有液体，加工就不能取得成功，因为薄膜被融化而不能在其上穿孔。詹姆森指出，可以认为，液体在超声波工作头工作过程中的存在可实现两个独立的、不同的功能。首先，液体的存在可作散热用，从而允许超声波振动作用在薄片材料上而不会使薄片材料因融化而改变或破坏。其次，液体的存在允许液体作为耦合介质而将来自超声波工作头的振动施加给薄片材料。
利用超声波对薄片材料穿孔是适宜的，因为它允许薄片快速运动进行加工，而不会产生浪费。在过去，在薄片上穿孔的方法已包括对片状材料冲孔。虽然在片状材料上冲小孔能产生所需要的穿孔效果，但冲孔将留下多余的芯子。这些芯子常常粘附在薄片材料上，从而产生不希望出现的后果，即它们会干扰最终产品的制造。
另一种在薄片材料上穿孔的方法包括使薄片材料通过加热的图案辊。这种方法最终通过熔融在薄片材料上形成小孔，从而形成适当穿孔的材料而不会有多余物粘附在薄片材料上。虽然它克服了在薄片材料上冲孔产生的问题，但加热滚筒的方法是一个很慢的过程。在加热的滚筒和图案砧座之间形成的间隙里，薄片材料被加热且在薄片材料上形成小孔。然后使薄片材料冷却，以避免小孔又被融化而恢复原状。所有这些加热、成型和冷却加工均要花费时间，且需要在该间隙的狭窄区域内进行这些加工。因此，这种加工进行得相当慢，这种方法不是在薄片材料上穿孔的合适方法。
因此，需要一种比加热滚筒方法快得多的、且与冲孔方法相比无多余物的在薄片材料上穿孔的方法。利用超声波在卷料上穿孔的方法克服了先前诸穿孔方法的缺陷。本发明利用超声波对卷料穿孔，从而不需要拉伸卷料，也不需要将液体与超声波振动组合在一起。
                      本发明的简要说明
针对现有技术中存在的上述问题和困难，我们提供一种在薄片材料上形成小孔的方法，这种材料具有约8密耳(0.2mm)或更大的厚度，而形成的各小孔的面积一般大于0.05mm2。该方法包括以下步骤：提供具有第一面和第二面的薄片材料，其中，薄片材料的至少一面涂敷有粘结剂，穿孔方法包括以下步骤：(1)将涂敷粘结剂的薄片材料置于一具有由一些凸出表面构成的图案的图案砧筒上，其中，凸出表面的高度等于或小于薄片材料和粘结剂的厚度；以及(2)使薄片材料经受具有至少每秒约10,000次、足够量的声波振动，从而在薄片材料和粘结剂上穿孔，且薄片材料和粘结剂钻出的小孔呈现出与图案砧筒上的凸出表面构成的图案相同的图案，其中，形成的各小孔的面积一般大于0.05mm2。
在另一实施例里，本发明包括一种在薄片材料上穿孔的方法，提供一具有第一面和第二面的薄片材料，其中该薄片材料的至少一面与一衬垫平面对合，而一种粘结剂可选择地涂敷在薄片材料上，该薄片材料和衬垫和可选择的粘结剂一起组合成复合片材料，在薄片材料和可选择的粘结剂上穿孔的方法包括以下步骤：(1)将复合片材料置于一具有由凸出表面构成的图案的图案砧筒上，其中，凸出表面的高度等于或小于薄片材料和可选择的粘结剂的厚度；以及(2)使复合片材料在安装着图案砧筒的地方经受具有至少每秒约10,000次振动的声波振动，其中，形成的各小孔的面积一般大于0.05mm2。这种方法的结果是，在薄片材料和粘结剂上钻出的小孔呈现出与图案砧筒上的凸出表面构成的图案相同的图案，而衬垫上没有穿孔。
在一些实施例里，可能希望将薄片材料/粘结剂复合片上的穿孔限制在该复合片的某一预定区域或若干预定区域内。通过只使薄片材料一部分经受超声波振动可以获得这个结果。作为替代，通过只使图案砧筒的一部分具有凸出表面也可以获得这个结果。
                        附图的简要说明
图1是可提供声波振动、以便在薄片材料上穿孔的装置的示意图；
图2是接受声波振动的薄片材料区域的详细视图，图2是图1中的虚线圆所示区域的部分视图；
图3提供了在图案砧筒和声波工作头之间的薄片材料的立体图；
图4是还包括声波工作头进一步细节的、图1所示装置的示意图。
                              定义
这里使用的术语“粘结剂”涉及到适于在诸如连续的片状材料之类的大表面上涂敷的任何压敏粘结剂。这种粘结剂的例子包括(但并不限于)丙烯酰氨树脂，聚丙烯酸酯，诸如聚α-烯烃之类的聚烯烃，天然橡胶或丁基合成橡胶，聚异戊二烯，聚氨酯，诸如苯乙烯-烯烃共聚物之类的嵌段共聚物，聚醚，以及根据需要有或没有增粘成分的聚酯。
这里使用的术语“小孔”涉及一般的线型孔或通道。这种小孔不同于也不包括具有较大弯曲路径的孔或通道，或者在薄膜上见到的孔。术语“小孔”进一步涉及到具有在约0.05到约70平方毫米之间面积的孔。小孔的这个面积是在线型通道或孔的最宽点处测得的。
这里使用的术语“衬垫”涉及任何适于粘结在薄片材料上的材料。这种衬垫一般在约2到10密耳(0.05到0.254毫米)厚度之间，而在本发明的较佳实施例里包括可从伊利诺斯州迪克森的多布特买到的涂敷硅树脂的剥离纸。
这里使用的术语“薄片材料”涉及平均厚度一般大于约8密耳(0.2毫米)的片状材料。平均厚度是这样测定的，通过在一给定的片状材料上任意选择6个位置，测量在各位置处的片状材料的厚度并精确到0.1密耳(0.002毫米)，然后平均这6个数值(将6个数值的总和除以6)。为了描述的目的，可使用一种或几种上面所述的片状材料进行合成以形成一薄片材料。
这里使用的术语“声波振动”涉及具有每秒至少约10,000次频率的振动。术语“声波振动”包括在现有技术中通常称作“超声波振动”的频率，这种在每秒约20,000到约400,000次范围内的振动在现有技术中是众所周知的。由于声波振动和超声波振动均适用于本发明的方法，因此术语“声波”和“超声波”在这里可互换使用。
这里使用的术语“聚合物”或“聚合的”涉及由叫做单体的5个或更多相同的组合单元的化学结合形成的大分子。
这里使用的术语“自然存在的聚合材料”涉及自然形成的聚合材料。该术语还意味着包括可由自然存在的材料再生的、诸如赛珞玢这样的材料，它可由自然存在的纤维素生成。这种自然存在的聚合材料的例子包括(但不限于)(1)诸如淀粉、纤维素、果胶、海藻胶(诸如琼脂等)、植物胶(诸如阿拉伯胶等)；(2)多肽；(3)诸如橡胶和杜仲胶之类的碳氢化合物；以及(4)诸如赛珞玢或脱乙酰壳多糖等再生材料。
这里使用的术语“弹性材料”或“弹性层”涉及在弯折、拉伸或压缩后基本上能恢复原状的任何材料。弹性材料包括(但不限于)硅树脂、聚氨酯、聚烯烃或泡沫带。
这里使用的术语“热塑性材料”涉及一种高分子聚合物，当它受热时软化，而当它冷却到室温时恢复原状。显示这种性能的自然物质是天然橡胶和各种蜡。其它的、作为例子的热塑性材料包括(但不限于)聚氯乙烯、聚酯、尼龙、碳氟化合物、诸如线型低密度聚乙烯之类的线型聚乙烯、聚氨酯预聚物、聚苯乙烯、聚丙烯、聚乙烯醇、己内酰胺、以及纤维素和丙烯酸树脂及它们的共聚体和共混料。
                     本发明的详细说明
现在参看附图，其中相同的标号表示相同的结构，图1是一能实现本发明方法的装置的示意图，该装置用标号10标示。工作时，提供一送料辊12，要穿孔的薄片材料14卷绕在其上。如上所述，术语“薄片材料”涉及平均厚度约8密耳(0.2毫米)或更厚的片状材料。例如，薄片材料14的平均厚度可在约5到250密耳(0.13到6.4毫米)的范围内。具体地说，薄片材料14的平均厚度可在约8到120密耳(0.02到3.05毫米)的范围内。更具体地说，薄片材料14的平均厚度可在约10到60密耳(0.254到1.5毫米)的范围内。
薄片材料14可由热塑性薄膜形成。该热塑性薄膜可由自一个集合选出的材料形成，该集合包括一种或几种聚烯烃，聚氨酯，聚酯，A-B-A’嵌段共聚物，其中，A和A’各是包括苯乙烯一半的热塑性聚合物端基，且A可以是和A’相同的热塑性聚合物端基，而B则是弹性体聚合物中段，诸如一共轭的二烯烃，或一低烯烃，或乙烯-乙酸乙烯共聚物。该聚烯烃可选自包括一种或几种线型低密度聚乙烯、聚乙烯或聚丙烯的集合。热塑性薄膜可是一填充薄膜，该填充薄膜可选自包括填充着淀粉、二氧化钛、石蜡、碳或碳酸钙的聚乙烯薄膜的集合。
在另一个实施例里，薄片材料可是无纺织品或泡沫。无纺织品涉及由加氢缠结的、可包括人造短纤维和粘合纤维的纺粘纤维或熔喷纤维形成的织品。无纺织品可通过现有技术中已知的任何传统的方法、包括气流纺和梳理和诸如纺粘和熔喷的无纬方法制成。美国专利第3,121,021号和第3,575,782号公布了这种方法和无纺织品的例子。无纺织品的一个例子包括(但不限于)可从明尼苏达州圣保罗的3M公司买到的3M商标的弹性无纺带(9906T)。诸如聚氯乙烯、聚乙烯和聚氨酯之类的泡沫也可作本发明的薄片材料用。适当的泡沫材料的一个例子包括(但不限于)可从明尼苏达州圣保罗的3M公司买到的3M商标的泡沫带(1773)。
在还有一个实施例里，薄片材料可是自然存在的聚合材料。例如，自然形成的聚合材料可选自包括赛珞玢、醋酸纤维素、胶原蛋白或角叉菜胶。
对于本技术领域的熟练人员来说，阅读了这里公开的内容后，其它适当的薄片材料是显而易见的。
在一个较佳的实施例里，薄片材料14的一个表面上基本上涂敷着粘结剂116，如图2所示。薄片材料14涂敷着粘结剂的侧面较佳的是被传送通过在超声波工作头50和图案砧筒32之间形成的间隙18，并使粘结剂朝向超声波工作头50。粘结剂116较佳的是层叠在一剥离衬垫30上，以降低当薄片材料14被传送通过间隙18时在粘结剂116和间隙18之间产生的摩擦。
可用于本发明的片状材料上的、较佳的压敏粘结剂是诸如授予乌尔里希的第RE24,906号美国专利描述的丙烯酸酯共聚物之类的粘结剂，具体地说是丙烯酸异辛酯∶丙烯酸等于96∶4的共聚物。还可以使用第4,737,410号美国专利公开的丙烯酸异辛酯：丙烯酸亚乙基辛酯(ethyleneoctyl)：丙烯酸三聚物。美国专利第3,389,827号，第4,112,213号，第4,310,509号和第4,323,557号公布了其它可用的粘结剂。这些可用的粘结剂还可含有诸如美国专利第4,737,410号公布的增粘剂。
如上所述，在较佳的实施例里，衬垫30粘结在薄片材料14的粘结剂涂层116上。将薄片材料14、粘结剂116和衬垫合并在一起称为复合片36。衬垫30较佳的是包括牛皮纸、或涂敷硅树脂的剥离纸或其它一些材料，以保护复合片36上的粘结剂116。衬垫30也限制了复合片36的拉伸。本发明最好是在薄片材料14未被拉伸的情况下传送通过间隙18。如果在将薄片材料14/粘结剂116传送通过间隙时不使用衬垫，可能需要一个比较复杂的运输或传送系统，以便在迫使薄片材料14通过间隙18且声波振动作用在它表面上时能确保薄片材料14基本上不被拉伸。本技术领域的熟练人员将会知道，如果在穿孔时接受穿孔处理的材料受到拉伸，则控制小孔的尺寸是非常困难的。此外，即使获得所需要的小孔尺寸，要获得稳定一致的小孔尺寸也是困难的，这是因为当材料受到拉伸时小孔尺寸会改变。
除了减少薄片材料受拉伸的优点外，衬垫30还提供了另一个优点，即有助于减少工作头50和图案砧筒32的磨损。由于图案砧筒32上的凸出表面或针34的高度使其不会在衬垫30上穿孔，因此衬垫30总是能在图案砧筒32和超声波工作头50之间提供缓冲作用，由此限制了砧筒和工作头的磨损。衬垫30还可作为隔热层，以及减少工作头50和复合片材料36之间的摩擦。
在另一个实施例里，薄片材料14可直接层叠在衬垫30上并用于本发明。
在一个较佳实施例里，复合片材料36被送入一(由图1中的虚线圆限定的)区域38内，复合片材料36在那里经受声波振动。复合片材料36离开送料辊12后直接输送给由声波工作头50和图案砧筒32形成的间隙18。在一个较佳实施例里，图案砧筒32是一滚筒形状，它由一传统的动力源(未画出)驱动。如果图案砧筒呈滚筒形状，它有助于复合片材料36被传送通过间隙18。如果没有使用衬垫与薄片材料结合在一起，这种运动有助于减少薄片材料的拉伸。
将声波振动提供给薄片材料14的组件最好参看图4，且该组件用标号40标示。组件40包括一电源装置42，它通过电源控制装置44将电力提供给一压电转换器46。如现有技术中已知的，由于转换器响应输入电能而发生振动，压电转换器46将电能转换成机械运动。将压电转换器46产生的振动以通常的方式传送给一机械运动助力器或增强器48。如在现有技术中已知的，机械运动助力器48可通过一已知的参数来增加振动(机械运动)的振幅，而该参数取决于助力器48的结构。在另一种传统方式里，机械运动(振动能)自机械运动助力器48传送给一传统的横杆边缘超声波工作头50。应该知道，也可使用其它类型的超声波工作头50。超声波工作头50也可安装在另一个助力器上以增加提供给薄片材料14的机械运动(振动)的振幅。
在超声波振动介入前由超声波工作头和图案砧筒施加给薄片材料的力叫做“施加力”。该施加力与由上面所述的超声波装置作用在薄片材料上的压力成正比。为了本发明的目的，作用在复合片材料上的“施加力”在一较宽的范围内变化。一给定的气缸或致动器可在约25至60磅/平方英寸(17,500至42,000公斤/平方米)之间工作，并仍可在薄片材料上产生可接受的小孔。术语“可接受的小孔”意味着该小孔在外观上基本上是均匀的符合所需尺寸。
图2是图1所示的区域38的示意图，其中，将声波振动提供给复合片材料36(如图1所示)。在一个较佳实施例里，超声波工作头50的末端54(未画出)几乎与图案砧筒32相切。当超声波振动冲击复合片材料时几乎垂直于该薄片材料，从而可形成最均匀的小孔。此外，由于它允许复合片材料36达到最快的线速度并仍能获得可接受的小孔，因此这种结构是较佳的。
虽然可能没有完全理解作用的机理，以及本申请不应该受任何特定的理论或作用机理的限制，但下面的描述可认为是本发明的工作机理。小孔是通过在薄片材料14/粘结剂116复合片上的定位熔融、并按照图案砧筒32的凸出表面或针34的图案形成的。经过这样处理的薄片材料不会被破坏，而仍维持它的整体性。通常，所产生的小孔数量等于在图案砧筒上表面上的凸出表面34的数量。
形成于薄片材料14和粘结剂116(如果涂敷了一层粘结剂)上的小孔的尺寸取决于若干可变参数。改变下列参数中的任何一个将改变形成于薄片材料14上的小孔尺寸。这些参数包括(1)薄片材料14的结构，(2)针34的表面积，(3)超声波或声波振动的振幅，(4)超声波或声波振动的频率，(5)工作头50和图案砧筒32及薄片材料14的导热性，以及(6)线速度。针的大小、振动的频率、振动的振幅和薄片材料的导热性直接关系到小孔尺寸。即，当这些参数中的任何一个增加时，所形成的小孔尺寸增加。相反，线速度与产生的小孔尺寸成反比关系。即，当线速度增加，在薄片材料14上形成的小孔尺寸将减小。
令人意想不到的是，在图案砧筒32上的针34的高度等于或略小于将被穿孔的材料的厚度。即，针的高度等于或小于薄片材料14的厚度。如果薄片材料上涂有一层粘结剂，针34的高度等于或小于薄片材料14和粘结剂116的组合高度。薄片材料14或薄片材料14/粘结剂116复合片高度与在其之下的凸出表面34的高度之差将随要穿孔的薄片材料14的类型而改变。高度较低的针34可用来对较一致的薄片材料14进行穿孔而不是对很少一致的薄片材料14进行穿孔。
在一个较佳的实施例里，在图案砧筒32上的凸出表面34通常是圆锥形，而在薄片材料14上产生的小孔是截头圆锥形。此外，凸出表面34可是矩形或棱锥形。在这种情况下，小孔的形状通常与图案砧筒上的凸出表面34的矩形或棱锥形一致，即小孔将呈通常的矩形或截头棱锥形。
本发明的另一个特征是，可在薄片材料14预定的区域上形成小孔。这可通过许多方法实现。例如，可只使薄片材料的某些区域接受超声波振动，这样，就只在这些区域内进行穿孔。此外，也可使全部薄片材料接受声波振动，而图案砧筒只在某个位置有凸出表面而其余是平的。由此，薄片材料14只在对应具有凸出表面的图案砧筒区域的区域上被穿孔。
一般来说，各小孔的面积通常约大于0.05平方毫米。即，各小孔的面积可在至少约0.05平方毫米至约70平方毫米范围内。例如，形成的各小孔的面积一般可在至少约0.05平方毫米至约30平方毫米范围内。较佳的是，形成的各小孔的面积一般可在0.05平方毫米至约0.5平方毫米范围内。更佳的是，形成的各小孔的面积一般可在至少约0.05平方毫米至约0.3平方毫米范围内。
现在可进行有关这种加工的大量的重要观察。例如，流体的存在对于本发明的加工(在薄片材料上穿孔)来说是不重要的。此外，为了在薄片材料上形成小孔，给薄片材料14提供张力是不需要的。在本发明的方法中，仅仅为了较好地引导和控制薄片材料，才需要一些作用在薄片材料14上的张力。在超声波工作头50和图案砧筒32之间的压力是由上述的施加力和超声波振动一起提供的。本发明的一个附加的和令人意想不到的特征是，本发明的方法可在涂有粘结剂的薄片材料上形成小孔。由于认为小孔是通过熔融形成于薄片材料和粘结剂上，人们将认为诸如粘结剂之类的粘性材料也可返流到小孔的，从而使小孔消失。然而，这不会发生，且本发明将令人惊奇地适合于在涂敷粘结剂的薄片材料上穿孔。
不同结构的图案砧筒32也可适用于本发明。例如，图案砧筒32可以是一块带有若干凸出部分的平板，各凸出部分用以引导来自声波工作头50的穿孔力。较佳的是，图案砧筒32是具有凸出表面34的圆柱形滚筒。如果图案砧筒32是带有许多凸出表面的圆柱形滚筒，最好将一弹性材料卷绕或涂敷在图案砧筒32上。适当的弹性材料的例子包括硅树脂、聚氨酯、聚烯烃或泡沫带。附加弹性材料被认为允许针34的高度有较大的可变性，由此形成可接受的小孔尺寸和深度。此外，如果在本发明的方法里使用衬垫30并在图案砧筒上附加弹性材料，可允许有较大范围的针34的高度，以获得穿孔的薄片材料14和不穿孔的衬垫30。
现在，将联系具体的例子来描述本发明，这些例子有助于本技术领域的熟练人员完全地和充分地理解本发明。下面的例子描述了不同的工作情况和适用于本发明的材料。下面的描述只是示范性的，并不是用来限制本发明。
                           例子
超声波焊机
图4示意显示的400系列布兰森超声波焊接装置(可从康涅狄格州丹伯里的布兰森超声波公司买到)使用一6.35cm气缸，它包括一1.27cm×15.24cm的钛工作头和一2∶1的助力器，它们在下面的各例子里被用来提供声波振动。在各例子里，启动超声波工作头将提供每秒20,000次的振动。
                            例1
该例子描述了不同的线速度，而按照本发明的施加力适用于在聚氨酯无纺织品上穿孔。
在上述的超声波焊机上使用一约7.62cm直径、2.54cm宽的转动砧筒，其上覆盖着0.508cm×0.508cm、高1.4mm的方形针，它们的中心间隔1.27mm，以便在由送料辊提供的薄片材料上形成有规则图案的小孔。该图案使薄片材料上的小孔沿机器运转方向间隔1.27mm(中心到中心)，沿垂直机器运转方向间隔1.27mm。这些小孔互相交错排列。
用来穿孔的复合片材料包括一由可买到的、基本重量为143.5g/m2的聚氨酯(Morthane PS440-200；莫顿国际股份有限公司)制成的熔喷无纺织品层，一在该无纺织品层上的、6格林(25g/m2)的、丙烯酸类粘结剂(60％的丙烯酸异辛酯∶丙烯酸等于94∶6，40％的Foral 85增粘剂(可从特拉华州威尔明顿的赫尔克里士公司买到))形成的涂敷层，以及一在该涂敷层上的、约0.0762mm厚的、由涂敷硅树脂的牛皮剥离纸1-80BKG-157和聚乙烯(伊利诺斯州迪克森的多布特化学公司)形成的衬垫。
复合片材料以各种速度传送通过由超声波焊机和图案砧筒形成的间隙，以便在薄片材料上穿孔。超声波焊机具有约3密耳(0.0762cm)的声波振幅而以可变的力施加在复合片材料上，如表1所示。产生的结果显示在下面的表1中。
                             表1
  复合片材料/试验编号      线速  度(m/min)   施加力(仪表压力kg/m2)    关于形成的小孔的说明   小孔尺寸(mm2)
  1.聚氨酯，粘结剂和衬垫     6.1     4570     薄片材料凸起，一些小孔形成     0.16
  2.聚氨酯，粘结剂和衬垫     12.2     7013     薄片材料凸起，一些小孔形成     0.16
  3.聚氨酯，粘结剂和衬垫     21.3     10547     薄片材料凸起，一些小孔形成     0.16
  4.聚氨酯，粘结剂和衬垫     30.5     14062     薄片材料凸起，一些小孔形成     0.16
  5.聚氨酯，粘结剂和衬垫，带有PET载体*     30.5     14062     在薄片材料和粘结剂上形成小孔     0.16
  6.聚氨酯，粘结剂和衬垫     6.1     7031     薄片材料凸起，形成比试验1多的小孔     0.16
  7.聚氨酯，粘结剂和     6.1     5625     薄片材料凸起，一些小孔形成，但比     0.16
衬垫 试验1少
*将0.036mm的聚对苯甲酸乙二醇酯作为在砧筒和聚氨酯层之间的载体层例2
本例子描述了本发明的方法在有或没有置于图案砧筒上的弹性材料情况下进行工作的情况。
用来穿孔的复合片材料包括一由可买到的、基本重量为143.5g/m2的聚氨酯(Morthane PS440-200；莫顿国际股份有限公司)制成的熔喷无纺织品层，一在该无纺织品层上的、6格林(25g/m2)的、丙烯酸类粘结剂(60％的丙烯酸异辛酯∶丙烯酸等于94∶6，40％的Foral 85增粘剂)形成的涂敷层，以及一在该涂敷层上的、约0.0762mm厚的、由涂敷硅树脂的牛皮剥离纸1-80BKG-157和聚乙烯(伊利诺斯州迪克森的多布特化学公司)形成的衬垫。熔喷织品和粘结剂的总厚度是0.343mm。
提供一直径约7.62cm、宽9.52cm的转动砧筒，它带有直径为1.016mm、高度0.381mm、中心间隔4.61mm的圆柱形针形成的图案。在第一次试验中，图案砧筒上覆盖着0.373mm厚度的熔喷聚氨酯织品层，它带有粘结剂而没有衬垫，粘结剂粘附在砧筒上。它作为砧筒上的弹性复盖层。该图案砧筒被用来在由一送料辊提供的薄片材料/粘结剂上形成有规则图案的小孔。
上述复合片材料以30.5m/min的速度传送通过由超声波焊机和图案砧筒形成的间隙。超声波焊机具有约0.0762cm的声波振幅，并以一可变的力施加在复合片材料上，如表2所示。表2描述了所产生的小孔。
    表2
  复合片材料   弹性叠层   施加力(仪表压力kg/m2)   小孔尺  寸(mm2)   关于形成的小孔从说明
  1.聚氨酯，粘结剂和衬垫   有   26,105   0.28   薄片材料和粘结剂被穿孔，衬垫未穿孔
  2.聚氨酯，粘结剂和衬垫   无   26,105   0.28   薄片材料和粘结剂被穿孔，衬垫部分穿孔
  3.聚氨酯，粘结剂和   无   21,903   0.28   薄片材料和粘结剂被穿孔，衬垫部分穿孔
衬垫
  4.聚氨酯，粘结剂和衬垫   无   17,578   0.28   薄片材料和粘结剂被穿孔，衬垫凸起
  5.聚氨酯，粘结剂和衬垫   无   14062   0.28   30％d薄片材料和粘结剂被穿孔；70％d的薄片材料凸起；衬垫凸起
例2中的薄片材料在试验4的情况下较佳。例3
本例子描述了具有不同结构的薄片材料可按照本发明的方法进行穿孔。此外，本例子还描述了可使用不同的材料作弹性叠层以供图案砧筒用。
试验1-5和8中的复合片材料包括一由可买到的、基本重量为143.5g/m2的聚氨酯(Morthane PS440-200；莫顿国际股份有限公司)制成的熔喷无纺织品(薄片材料)层，一在该无纺织品层上的、6格林(25g/m2)的、丙烯酸类粘结剂(60％的丙烯酸异辛酯∶丙烯酸等于94∶6，40％的Foral 85增粘剂)形成的涂敷层，以及一在该涂敷层上的、约0.0762mm厚的、由涂敷硅树脂的牛皮剥离纸1-80BKG-157和聚乙烯(伊利诺斯州迪克森的多布特化学公司)形成的衬垫。熔喷薄片材料和粘结剂的总厚度是0.343mm。
试验7中的复合片材料包括Microfoam带，它带有来自明尼苏达州圣保罗的3M公司的、可作医用带的衬垫。试验7中的复合片材料包括Volara泡沫带，它带有来自明尼苏达州圣保罗的3M公司的衬垫。该Volara泡沫底层的厚度是0.89mm，而衬垫的厚度是0.178mm。
一直径约7.62cm、宽约9.52cm的转动砧筒上覆盖着直径1.016mm、高度0.381mm、中心间隔4.61mm的圆柱形针，该砧筒上还覆盖着表3所示的各种弹性叠层，针的有效高度由在转动砧筒上的针的高度减去弹性叠层的厚度确定，并已由表3相对各弹性叠层给出。
复合片材料以30.5m/min的线速度被传送通过由超声波焊机和图案砧筒形成的间隙。超声波焊机具有约0.0762mm的声波振幅，而施加在复合片材料上的力的变化情况如表3所示，以便给薄片材料提供小孔。施加力由装置上的表盘式调节器调整。
      表3
复合片材料 弹性叠层 针  高(mm) 有效针高 施加力(kg/m2) 形成的小孔的说明 小孔尺寸
(mm) (mm2)
1.聚安酯，粘结剂和衬垫 0.102mm(聚氯乙烯)塑料薄膜带第471号(3M公司) 0.381 0.0279 25312至29530 聚安酯和粘结剂穿孔良好；衬垫凸起 0.3
2.聚安酯，粘结剂和衬垫 0.203mm(聚氯乙烯)塑料薄膜带第471号(3M公司) 0.381 0.178 25312 聚安酯凸起，在聚安酯和粘结剂上形成一些小孔 0.3
3.聚安酯，粘结剂和衬垫 0.203mm(聚氯乙烯)塑料薄膜带第471号(3M公司) 0.381 0.178 29530 聚安酯凸起，在聚安酯和粘结剂上形成一些小孔 0.3
4.聚安酯，粘结剂和衬垫 可从明尼苏达州北圣保罗的保拉塑料公司买到的0.152mm机械级拉伸薄膜(聚乙烯) 0.381 0.229 23905 聚安酯和粘结剂穿孔良好；衬垫凸起 0.3
5.聚安酯，粘结剂和衬垫 0.140mm聚酯带第351号(3M公司) 0.381 0.241 26718,30936,35155和39374 聚安酯和粘结剂的穿孔较好；衬垫有些凸起 0.3
6.带有衬垫的 无 0.381 0.381 28124至 聚安酯和粘结剂穿孔良好； 0.08
MicrofoamTM带 31640 衬垫有些凸起
7.带有0.178mm衬垫的VolaraTm泡沫带(0.89mm) 无 0.381 0.381 14062 聚安酯和粘结剂穿孔良好；衬垫有些凸起 0.38
8.聚安酯，粘结剂和衬垫 已去掉衬垫的0.889mmVolara泡沫带 0.381 0 31640 聚安酯和粘结剂穿孔良好；衬垫有些凸起 0.3
应该理解，只是为了描述的目的给出本发明上述较佳实施例的详细说明，对于本技术领域的熟练人员来说，阅读了这里的详细说明后，在本发明的精神和范围内就可清楚地了解许多其它的变化和改进。

Claims (10)

1.一种在薄片材料上形成小孔的方法，该薄片材料具有第一面和第二面，其中该薄片材料的至少一面与一衬垫平面对合，而一种粘结剂可选择地涂敷在薄片材料上，该薄片材料和可选择的粘结剂和衬垫一起组合成一复合片材料，此外，形成的各小孔的面积大于0.05平方毫米，该方法包括以下步骤：
(1)将复合片材料置于一具有由凸出表面构成的图案的图案砧筒上，其中，凸出表面的高度小于或等于薄片材料和可选择的粘结剂的厚度；以及
(2)使复合片材料经受足够量的声波振动，以便在薄片材料和可选择的粘结剂上穿孔；以及
在薄片材料和粘结剂钻出的小孔呈现出与图案砧筒上的凸出表面构成的图案相同的图案，而衬垫上没有穿孔。
2.如权利要求1所述的方法，其特征在于，衬垫是由涂敷硅树脂的剥离纸组成。
3.如权利要求1所述的方法，其特征在于，薄片材料包括无纺织品。
4.如权利要求1所述的方法，其特征在于，薄片材料包括薄膜。
5.如权利要求1所述的方法，其特征在于，粘结剂选自基本由丙烯酸类粘结剂组成的集合。
6.如权利要求1所述的方法，其特征在于，图案砧筒是带有凸出表面的圆柱形滚筒。
7.如权利要求1所述的方法，其特征在于，薄片材料的厚度至少是8密耳(0.2毫米)。
8.如权利要求1所述的方法，其特征在于，声波振动在每秒15,000至40,000次范围内。
9.一种在薄片材料上形成小孔的方法，该薄片材料具有第一面和第二面，其中该薄片材料的至少一面与一衬垫平面对合，而一种粘结剂涂敷在薄片材料的至少一面上，该薄片材料和粘结剂和衬垫一起组合成一复合片材料，此外，形成的各小孔的面积大于0.05平方毫米，该方法包括以下步骤：
(1)将复合片材料置于一具有由凸出表面构成的图案的图案砧筒上，其中，凸出表面的高度小于或等于薄片材料和粘结剂的厚度；
(2)使复合片材料在没有液体的情况下经受足够量的声波振动，以便在薄片材料和粘结剂上穿孔，但不对衬垫穿孔；以及
在薄片材料和粘结剂钻出的小孔呈现出与图案砧筒上的凸出表面构成的图案相同的图案，而衬垫上没有穿孔。
10.一种具有第一面和第二面的薄片材料，其中该薄片材料的至少一面涂敷一种粘结剂，并具有诸小孔，其中，各小孔大于0.05平方毫米，该小孔由包括以下步骤的方法形成：
(1)将涂敷粘结剂的薄片材料置于一具有由凸出表面构成的图案的图案砧筒上，其中，凸出表面的高度等于或小于薄片材料和粘结剂的厚度；以及
(2)使薄片材料经受足够量的声波振动，以便在薄片材料和粘结剂上穿孔；以及
在薄片材料和粘结剂上钻出的小孔呈现出与图案砧筒上的凸出表面构成的图案相同的图案。
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JPH10508542A (ja) 1998-08-25
JP2007062010A (ja) 2007-03-15
AU3831795A (en) 1996-05-31
WO1996014191A1 (en) 1996-05-17
MX9703340A (es) 1997-07-31
ZA959376B (en) 1997-05-06
DE69533878T2 (de) 2006-01-12
EP0790884B1 (en) 2004-12-22
EP0790884A1 (en) 1997-08-27
KR970706948A (ko) 1997-12-01
BR9509635A (pt) 1998-01-06
US5735984A (en) 1998-04-07
AU696075B2 (en) 1998-09-03

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