CN1353629A - 高速压花和粘接剂涂敷方法及装置 - Google Patents
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Abstract
本发明的方法包括步骤:(a)将热熔性粘接剂涂敷在以初始切向速度回转的加热滚筒上;(b)将粘接剂碾压至较小厚度并使粘接剂加速通过多个相邻加热胶水涂敷滚筒之间的一系列计量间隙;(c)将粘接剂涂敷在以比初始切向速度高的切向线速度回转的均匀加热的胶水涂敷滚筒上;(d)将粘接剂涂敷在第一作有图形的压花滚筒上,该滚筒与具有与第一压花滚筒图形互补图形的第二作有图形的压花滚筒啮合;两个压花滚筒均加热;(e)片材坯料在第一和第二压花滚筒之间以切向线速度通过以同时在坯料上压花和将粘接剂涂敷在该坯料上,故粘接剂在压花凸起之间形成粘接剂图形;(f)将坯料从第二压花滚筒转移至第一压花滚筒;(g)从第一压花滚筒上剥下坯料;(h)冷却坯料。
Description
技术领域
本发明涉及压花和将粘接剂涂敷在薄膜坯料上的方法及装置。
背景技术
包括防止无意中被接触的压敏粘接剂薄层的三维片材,以及其制造方法和装置,已经开发出来,并在下列美国专利中作了详细的说明。这些专利是:(1)1997年9月2日授予Hamilton和McGuire的题为“压紧时可与目标表面密封并可取下的复合材料及其制造方法”的美国专利第5662758号;(2)1999年2月16日授予Hamilton和McGuire的题为“具有一种由可变形的固定器(stand off)保护的物质的材料及其制造方法”的美国专利第5871607号;(3)1996年11月8日以Mc Guire、Tweddell和Hamilton名义提交的、题为“三维抗套叠片材及其制造方法与装置”的、与本发明具有共同受让人同时待审的美国专利申请第08/745339号(准许的);(4)1996年11月8日以Hamilton和McGuire名义提交的、题为“改进的存贮包装材料”的美国专利第08/745340号,所有这些专利在此引用作为参考。
虽然,在这些专利申请/专利中所述的制造这种材料的方法和装置,适合于以较小规模地制造这种材料,然而,该方法和装置的速度受到设计的限制。换句话说,生产这种材料的过程和设备的最大运行速度受到下述因素的限制:运动零件的尺寸或重量;热量施加到可变形基片材料上的速率;力加在该基片上,使该基片变形成所需形状的速率;和/或粘接剂可以涂敷在该基片和/或中间装置元件上的速率。在以商业规模生产这种材料的经济性考虑中,这种方法和装置的工作速度是主要因素。
因此,希望能提供一种适于高速生产这种三维片材和涂敷粘接剂的方法和装置。
发明内容
本发明提供了一种方法,包括步骤:(a)将热熔性粘接剂涂敷在以初始切向速度回转的加热滚筒上;(b)将粘接剂碾压至较小厚度并使粘接剂加速通过多个相邻加热胶水涂敷滚筒之间的一系列计量间隙;(c)将粘接剂涂敷在以比初始切向速度高的切向线速度回转的均匀加热的胶水涂敷滚筒上;(d)将粘接剂涂敷在第一作有图形的压花滚筒上,该滚筒与具有与第一压花滚筒图形互补图形的第二作有图形的压花滚筒啮合;两个压花滚筒均加热;(e)片材坯料在第一和第二压花滚筒之间以切向线速度通过以同时在坯料上压花和将粘接剂涂敷在该坯料上,故粘接剂在压花凸起之间形成粘接剂图形;(f)将坯料从第二压花滚筒转移至第一压花滚筒;(g)从第一压花滚筒上剥下坯料;(h)冷却坯料。
附图说明
虽然本说明书以具体指出并明确提出本发明权利要求的权利要求书作为结尾,但通过下面结合附图对优选实施例的说明,将会更好地理解本发明。附图中,相同的附图标记表示相同的元件,其中:
图1为根据本发明的方法和装置的示意图;
图2为图1中装置的局部放大图,示出了在压花滚筒之间粘接剂传送步骤:
图3为本发明所用的无定形图形的有代表性实施例的四个相同“拼接图形”的平面图;
图4为将图3中四个“拼接图形”移得更靠近以示出该图形边界匹配的平面图;
图5为在本发明的图形生成等式中引用的尺寸示意图;和
图6为在本发明所使用的图形生成等式中引用的尺寸示意图。
具体实施方式
过程和装置
图1表示本发明的方法和装置10的示意图。该装置基本上由二个互相啮合的压花滚筒15和16、多个胶水计量/涂敷滚筒11~14、压力滚筒17,剥离滚筒18和冷硬的S形包裹物19构成。压花滚筒是钢制的,在其上面腐蚀形成匹配的压花图形,该图形是互锁的,用以在从该二个压花滚筒之间通过的片材坯料上进行压花。带有凹坑和升高的台阶的滚筒称为阴压花滚筒15,而带有升高凸块和凹陷平台的滚筒称为阳压花滚筒16。该阴压花滚筒的表面上优选涂有可除去的涂层。胶水涂敷/计量滚筒11~14是普通钢制的或涂敷橡胶的钢制的二者互相交替的排列。胶水涂敷滚筒14(胶水系统中的最后一个滚筒)总是由涂敷橡胶的钢制成的。压力滚筒17和剥离滚筒18也是由涂敷橡胶的钢制成的。冷硬的S形包裹物由空心的钢制滚筒19组成,在该滚筒的外表面上有可除去的涂层,冷却剂可通过该滚筒流动。图1中的箭头表示滚筒的回转方向。
更具体地说,参见图1,粘接剂(例如热熔性的对压敏粘接剂)40,通过加热的槽形模子9,挤出在第一回转滚筒11的表面上。该槽形模子由热熔性粘接剂供应系统(带有加热的漏斗和变速齿轮泵,未示出)通过加热的软管供料。第一胶水计量滚筒11的表面速度,比要压花和涂粘接剂的片材坯料50的名义切向线速度低得多。计量间隙在图1中表示成计量站1、2和3。剩下的胶水计量滚筒12~14的转速逐渐加快,因此,胶水涂敷间隙(即计量站)4处的表面速度是匹配的。在该计量站4处,胶水40从胶水涂敷滚筒14,转移至阴压花滚筒15上。胶水40与阴压花滚筒表面一起运行至计量站5,在该处与通过阳压花滚筒16送入计量站5的聚合物坯料50结合。
在计量站5处,聚合物坯料50被压花,并同时与胶水40结合,形成涂敷粘结剂的坯料60。粘贴在滚筒15表面上的坯料60,与该滚筒表面一起运行至计量站6,在该处橡胶涂层的压力滚筒17将压力加至该坯料的粘有胶水的部分上。仍旧粘贴在阴压花滚筒15上的坯料60运行至计量站7,在该处通过剥离滚筒18将坯料60从该阴压花滚筒15上剥离下来。然后,最终涂敷了粘接剂的坯料60运动至计量站8处的冷硬的S形包裹物19处,并冷却以增加其强度。
粘接剂(或胶水)40只涂敷在该阴压花滚筒15的台阶区域上。这点可通过小心地控制阴压花滚筒与胶水涂敷滚筒之间的间隙以及在计量站4处的径向振摆而实现。控制阴压花滚筒15和胶水涂敷滚筒之间的间隙可使布满胶水的橡胶滚筒14只将胶水涂在上述台阶上,而不把胶水压挤至该台阶之间的凹部或凹坑中。
该胶水涂敷滚筒14为涂敷橡胶的钢制滚筒。在特定的过程中,磨削该橡胶涂层,使径向振摆公差的总读数大约为0.001英寸。在机器中,利用精密的楔块来控制该间隙。利用橡胶涂层来:(1)保护阴压花滚筒15上的涂层,不致因为金属对金属的接触而破坏;和(2)使上述胶水涂敷滚筒,非常轻地压紧该阴压花滚筒,使橡胶的挠曲补偿压花滚筒和胶水涂敷滚筒的实际径向跳动,以便将胶水均匀地涂在阴压花滚筒台阶的每个地方。
胶水涂敷滚筒14轻轻地压在阴压花滚筒15上,使橡胶表面的挠曲补偿压花滚筒和胶水涂敷滚筒的径向跳动。但这种挠曲不应太大,以致将胶水压挤入阴压花滚筒15表面上的凹坑中。为了防止胶水转移至坯料上的压花凸起的顶部,使胶水只涂敷在阴压花滚筒15的台阶上是很重要的。压花凸起顶部上的粘接剂,可使该顶部在由于压花凸起的压碎而使坯料具有某种活性之前具有粘接剂的性质。
所使用的粘接剂或胶水的性质是高弹性的,因此当胶水从上述固定槽形模子9上的静止状态转变至高的切向线速度时,可以使胶水延伸和破裂,或者在第一计量滚筒上没有粘接剂。为了减少胶水的延伸率,首先将胶水涂在慢速运动的滚筒上,然后通过一系列的计量间隙(计量站1、2和3),将胶水碾压成极薄的胶水薄膜,并加速至所希望的切向线速度。
胶水涂敷滚筒的直径必需磨削至精确的公差,并保证其精确的径向振摆,以便保持胶水计量和加速所需要的精确的滚筒之间的间隙尺寸。典型的径向振摆公差的总读数为0.00005英寸。胶水涂敷滚筒必须在圆周方向和横跨机器运动方向上均匀地加热,以避免由热诱导产生的滚筒隆起或径向振摆。已经发现,在滚筒采用电加热的情况下,加热器出故障就会产生较大的径向振摆,以致妨碍胶水均匀地涂敷在坯布上。在这种情况下,要使用电流表来指示加热器的故障。通过轴承和滚筒轴的热损失会造成滚筒隆起,这也会妨碍胶水均匀地涂敷。通常,滚筒的轴承座也必需加热,以防止在机器运动的横向方向上出现温度梯度。
优选的是,阴压花滚筒15包括涂敷在台阶表面和台阶之间的凹坑或凹部表面上的一个可除去的涂层。为了使粘接和取下最好地结合,该可取下的涂层和胶水的性质必须被仔细地进行平衡考虑。该涂层必需能允许非常热(一般可达300~350°F)的胶水转移至阴压花滚筒上,并且在压花滚筒的温度(一般为160~180°F)下,能取下该涂有粘接剂的聚合物薄膜坯料。如果该可取下的涂层的粘接力太小,则胶水不能从胶水涂敷滚筒转移至阴压花滚筒上;同时,如果该可取下的涂层的粘接力太大,则最终的涂有粘接剂的坯料不可能在聚合物薄膜不撕破或拉长的情况下从阴压花滚筒的表面下取下。
薄膜应在最高的压花温度下进行压花,以得出清新的、厚度大的压花凸起;并且能用较小的剥离力,将涂有胶水的薄膜坯料从阴压花滚筒上取下。然而,压花滚筒的温度必须低于薄膜坯料的软化点温度,以便最终粘接剂涂层的坯料具有足够的拉伸强度,以从该阴压花滚筒上取下。取下温度和薄膜软化温度之间的平衡,是确定高速工作的成功的工作条件的关键参数。
剥离滚筒协助在不破坏薄膜的情况下,从该阴压花滚筒上取下最终的产品。由于产品(薄膜坯料)是用胶水粘接在阴压花滚筒的表面上的,因此在剥离点可产生非常大的力。剥离滚筒将这种很大的力局限在坯料的极短长度上,使坯料变形小,并可更好地控制剥离角度。为了使薄膜性质一致及防止薄膜具有过早被激活而显现粘接剂性质的区域,防止最终产品的变形是很重要的。
必须小心地控制阳压花滚筒与阴压花滚筒之间的啮合量或啮合程度,以防止滚筒或薄膜坯料损坏。压花滚筒的外表面磨削至其径向振摆公差的总读数为0.00005英寸。在机器中,啮合由精确的楔块控制。压花滚筒的啮合决定了薄膜的最终厚度(即,压花凸起的最终高度)。
另一个重要的标准是阳压花滚筒与阴压花滚筒之间的配合或相适应性。一种有用的技术是用光刻方法制造一个滚筒,并利用该滚筒作为“主导滚筒”,去制造另一个作为其底片图像的滚筒。还必需将设备设计成可以保持啮合的压花滚筒的精确同步性。
为了允许精确地控制胶水转移温度和从压花滚筒上取下的温度,压花滚筒和胶水涂敷滚筒都是单独加热和控制的。
使用图形形状互补的、互相啮合的阳压花滚筒与阴压花滚筒,在压花和粘接过程步骤中,可以充分地支承薄膜坯料,保证在薄膜材料内力的适当分布。与利用开放的支承结构-例如,将要变形成孔或凹部的坯料的一部分是不被支承的有孔带或滚筒-对薄膜进行热成形或真空成形的情况相反,充分支承坯料,可以增加使坯料变形的速率,而不会损坏坯料,因此可使生产速度更加提高。在压花步骤过程中,对薄膜同时涂敷粘接剂,可使粘接剂精确地重合在压花凸起之间的坯料不变形的部分上。
精确控制粘接剂,特别是涂在阴压花滚筒上的粘接剂层的厚度和均匀性,是高速生产高质量产品的重要因素。特别是在粘接剂的加入量很小的情况下,在粘接剂从一个滚筒转移至另一个滚筒的过程中,即使粘接剂厚度稍微改变一点,也可以在粘接剂涂敷在压花滚筒上时,将滚筒间的间隙覆盖。同时,粘接剂厚度的改变还可导致在压花滚筒的某些区域上,粘接剂过多,这样会污染滚筒中的凹部,或造成粘接剂不能完全转移至坯料上,和粘接剂积存在压花滚筒上。
图形生成
图3和图4示出利用以Kenneth S.McGuire名义提交的与本发明具有共同受让人同时提出同时待审的题为“无定形图形的接合和扩展方法”的美国专利申请中详细说明的算法所产生的图形20,其在此引用作为参考。从图3和图4可看出,当拼接图形20靠近时,在其边界上没有出现接缝。同样,如果例如通过将图形卷绕在带或滚筒上而将单一图形或拼接图形的相对边缘布置在一起,同样不会出现视觉上可辨识的接缝。
这里所用术语“无定形的”是指各个组成元素没有容易察觉的组织、规律性或排列方向的图形。术语“无定形的”这个定义一般指在“韦氏第九版新编大学字典”中相应定义的术语的普通意义。在这种图形中,一个元素相对于其相邻元素的排列方向和布局与下一个元素的排列方向和布局无关。
与此相反,这里所用的术语“阵列”是指:组成元素有规律、有序的分组和布局的图形。术语“阵列”的定义也是指“韦氏第九版新编大学字典”中相应定义的术语的普通意义。在这种阵列中,一个元素相对于相邻元素的排列方向和布局,与下一个元素的排列方向和布局有关系。
三维突起部分的阵列图形的有序程度,与坯料的套叠程度大小有直接关系。例如,在封闭的六边形阵列中,尺寸和形状均匀的空心突起部分的高度有序的阵列图形中,每个突起部分都是任何其它突起部分的横向重复。通过使叠加的坯料或在给定方向上突出部分的间隔不多于一个的各个坯料部分错开,就可使这种坯料的区域(如果不是整个坯料的话)套叠起来。虽然,一定程度的有序会带来一定程度的套叠,但是,有序程度越低,则套叠的趋势越小。因此,由于突出部分的无定形、无序的图形,可以表现出最大可能程度的抗套叠能力。
具有基本上为无定形三维突起部分的二维图形的三维片材也表现出“同型性”。这里所用术语“同型性”及其词根“同型的”是指:在图形的一个限定区域中(不论这个区域是否在图形内),几何和结构性质都基本上是均匀的。术语“同型的”的定义,一般就是根据“韦氏第九版新编大学字典”中相应定义的术语的普通意义。作为例子,包括对于整个无定形图形而言,大量突出部分区域内的许多坯料性质基本上是相同的。这些性质包括:突起部分的面积、突起部分数目的密度、总的突起部分的壁面长度等。当希望坯料整个表面均匀时,对坯料的物理和结构性质,特别是对诸如突起部分的抗压碎性的这样一些在坯料表面法线方向测出的性质等,进行修正是很希望的。
使用具有三维突出部分的无定形图形还有其它优点。例如,由在材料平面内初始是各向同性的材料制成的三维片材,其坯料的物理性质在该材料平面内的各个方向上一般也是各向同性的。这里所用的术语“各向同性的”是指:在材料的平面内,在所有方向上,坯料的性质基本上相同。术语“各向同性的”的定义,也是“韦氏第九版新编大学字典”相应定义的术语的普通意义。无需理论证明,材料的这种性质是由于在无定形图形内,三维突起部分的无序、无定向排列造成的。相应地,坯料性质随着坯料方向而变化的有方向性的坯料材料,在将无定形图形加在该材料上之后,也会具有同样的性质。例如,如果初始材料的拉伸性质是各向同性的,则这种片材在材料平面内的任何方向上的拉伸性质基本上是一致的。
这种无定形图形其物理意义相当于,在该图形内,如同从任一给定点发出的射线一样,在任何一个给定方向上向外所画的一条线上测量的每单位长度上等价突出部分统计数目。其它的等价统计参数包括:突出部分的壁面数目、突出部分的平均面积,突出部分之间的总平均间隔等。相对于坯料平面上方向的结构几何形状的等价形状,可以转换为有方向性的坯料材料的等价性质。
现在再来看阵列的概念,以便说明阵列与无定形图形之间的差别。因为阵列是在物理意义上的定义“有序的”,因此,突出部分的尺寸、形状、间隔和/或排列方向都是有规律的。相应地,对于诸如:突出部分的壁面数目、突出部分的平均面积、突出部分之间的平均总间隔等参数,根据射线延伸方向的不同,从图形中给定点画出的线或射线数目不同;而对于有方向性的坯料的性质,则要作相应改变。
在优选的无定形图形内,坯料上突出部分的尺寸、形状、排列方向以及相邻突出部分中心之间的间隔,优选是不均匀的。无需理论证明即可知,相邻突出部分的中心对中心的间隔不同,在减少面对背的套叠发生方向起着重要作用。从物理意义上说,图形中突出部分的中心对中心的间隔差别形成各突出部分之间的空间,相对于总的坯料,位于不同的空间位置。因此,一个或多个坯料的叠加部分之间的突出部分/空间位置的“匹配”可能性是很小的。另外,在叠加的坯料或坯料一部分上的多个相邻突出部分/空间的“匹配”可能性非常小,这是由于突出部分图形的无定形性质决定的。
在完全无定形的图形中,优选的是,至少在设计者规定的边界范围内,中心对中心的间隔是随机的,因此,在坯料平面内任一给定的角度位置上,最接近的相邻的突出部分对给定的突出部分的位置差别是相同的。坯料的其它物理几何特性,例如:突出部分的侧面数目、每个突出部分内的夹角、突出部分的尺寸等,在该图形的边界条件内优选也是随机的或至少是不均匀的。然而,尽管有可能以及在某些情况下希望相邻的突出部分之间的间隔是不均匀的和/或随机的,但选择可以互锁在一起的多边形形状有可能使相邻突出部分之间的间隔均匀。如下文所述,这对于本发明的三维抗套叠的片材的某些应用是特别有用的。
由于带有一个或二个侧边的多边形可形成一条线,因此这里所用的术语“多边形”(及其形容词“多边形的”)是指:带有三个或多个侧边的一个二维几何图形。这样,三角形、四边形、五边形、六角形等都包括在术语“多边形”内;至于曲线形状,例如圆、椭圆等,因其具有无限多的边数,也包括在术语“多边形”内。
当描述不均匀特别是非圆形和不均匀间隔的二维结构的性质时,使用“平均”量和/或“等价”量是有用的。例如,在表征间隔是按中心对中心计算,或单独的间隔的二维图形物体之间的线性距离关系时,“平均”间隔对说明最终结构是有用的。其它可用平均量来说明的量包括:物体所占表面面积的比例、物体面积、物体圆周、物体直径等。对于诸如物体圆周和物体直径之类的其它尺寸,如果是非圆形的物体,则可以如在液压领域中常做的那样,通过构造假设的等同直径作为近似。
坯料的三维空心突出部分的总随机图形,理论上是不会有面对背的套叠的,这是因为每个截头体的形状和排列方式都是独一无二的。然而,设计这样完全随机的图形是非常费时间和复杂的,而制造适当成形结构的方法也是复杂的。根据本发明,通过设计使一些相邻单元或结构彼此有特定关系,由这些单元或结构形成的总的几何特性也是特定的,但单元或结构的精确尺寸、形状或排列方向是非均匀和非重复的,可以得到没有套叠的图形。这里所用术语“非重复的”是指:结构和形状相同的图形或结构不会在规定区域内的任何两个位置出现。虽然,在所关注图形或区域内,可能有多于一个的给定尺寸和形状的突出部分,但在它们周围存在有其它尺寸和形状不均匀的突出部分,实际上排除了相同的一组突出部分出现在多个地方的可能性。换句话说,在所关注的整个区域内,突出部分的图形都是不均匀的,使得在总的图形内,没有一组突出部分与其它任一类似组的突出部分是相同的。即使在突出部分本身叠加在单一匹配的凹部上的情况下,三维片材卷轴的强度也可以防止包围给定突出部分的该材料的任何区域产生大量套叠,围绕所关注单一突出部分的多个因为该突出部分周围的其它许多突出部分的尺寸、形状和中心对中心的是间隔,与其它突出部分/凹部周围的不同。
曼彻斯特大学的Davies教授研究了多孔的蜂窝状陶瓷膜片,更具体地说,已经生成了这种膜片的分析模型,可以进行数学建模,去对真实的性能进行仿真。这项工作更详细地在刊登于“膜片科学杂志”1995年第106期89~101页上的,作者为J.Broughton和G.A.Davies的、题为“多孔蜂窝状陶瓷膜片:一种描述阳极氧化物膜片结构的随机模型”的文章中作了说明。这里引用该文章供参考。其它有关数学建模的技术更详细地在下列文章中作了说明:“计算机杂志”1981年第24卷,第2期第167~172页刊登的,作者为D.F.Watson的,题为“利用Voronoi多面体计算n-维Delauney棋盘形布置”;以及在“分离科学和工艺”1993年第28(1-3)期,821-854页上刊登的、作者为J.F.F.Lim,X.Jia,R.Jafferali和G.A.Davies的、题为“描述多孔陶瓷膜片结构的统计模型”。这里引用这二篇文章供参考。
作为该项工作的一部分,Davies教授基于二度空间的有约束的Voronoi棋盘布置,开发了二维多边形图形。利用该方法,再参考上述公开文献,在有边界(预定的)平面内,在随机位置上设置成核点;该成核点的数目与在最后完成的图形中所希望的多边形数目相等。计算机程序从每个成核点以相等的速率同时沿径向方向“生长”出作为圆的每个点。当从相邻的成核点出来的生长前沿相交时,则生长停止,并形成一条边界线。每一条这种边界线形成一个多边形的边,边界线的交点形成多边形的顶点。
虽然,这个理论背景对理解这些图形是怎样生成的及这些图形的性质是有用的,但仍存在逐步重复上述数值,将成核点向外扩展至整个所关注的区域,直至完成该图形的问题。因此,为了快速地进行这个过程,最好在给定适当的边界条件和输入参数的条件下,编写计算机程序来进行这些计算,并输出所希望的输出值。
根据本发明,生成图形的第一步是建立所要图形的尺寸。例如,如果希望建立10英寸宽和10英寸长的图形,以便任意构成圆筒或条带以及板,则X-Y坐标系中的X的最大尺寸(Xmax)为10英寸,Y的最大尺寸(Ymax)为10英寸(反之亦然)。
在确定了坐标系和最大尺寸之后,下一步就是确定在规定的图形边界内生成所希望的多边形的“成核点”的数目。这个数目为0和无穷大之间的一个整数,应根据在最终图形中的多边形的平均尺寸和间隔来选择。较多的成核数目较多对应于较小的多边形,反之亦然。确定适当的成核点或多边形数目的一种有用的方法是,计算充满所要成形结构所需要的人造假设的尺寸和形状均匀的多边形数目。如果这个人造图形为一组规则的六边形30(见图5),其边对边的尺寸为D,六角形之间的间隔为M,则六角形的数目密度N为:
我们发现,利用这个等式计算所生成的无定形图形的成核点密度所得多边形的平均尺寸,非常接近假设六边形的尺寸(D)。一旦成核点密度已知,则图形中所用的成核点总数可通过将该密度乘以图形的面积(本例中为80平方英寸)而得到。
下一步需要随机数发生器。可以使用本领域的技术熟练人员公知的任何适当的随机数发生器,包括需要“种子数”或使用目标确定的开始值(如,按年月日顺序的时间)的随机数发生器。许多随机数发生器都提供0~1之间的一个数,下文中的讨论假设也使用这种发生器。如果结果可以转换为0~1之间的某个数,或使用适当的转换因子,则也可使用带有不同输出的发生器。
编写计算机程序,使该随机数发生器迭代所希望的次数,以产生多个所需要的随机数。该随机数的数目等于以上所计算的“成核点”数目的二倍。当产生随机数时,将交替的数乘以最大的X尺寸或最大的Y尺寸,以形成随机的一对X和Y坐标,在该坐标系中,所有的X值均在0~Xmax之间,所有的Y值均在0~Ymax之间。这些值作为数目与“成核点”数目相等的(X,Y)坐标对存储起来。
该点是本发明与先前Me Guire等人的专利申请中所述的图形生成算法不同的地方。假设希望图形的左边缘和右边缘“啮合”,即能“拼接”在一起,则应在10英寸见方的方形的右侧边上加上宽度为B的边界(图6)。所需边界的尺寸取决于成核点密度;成核点密度越高,所需的边界尺寸越小。计算该边界宽度B的一种方便的方法是,再次使用上述和图5所示的假设的规则六边形组。一般,在该边界中至少应加入三列假设的六边形,这样,边界宽度可按下式计算:
B=3(D+H)
现在,任何一个坐标为(X,Y)(X<B)的成核点P,将作为新坐标为(Xmax+X,Y)的另一个成核点P′,复制在该边界中。
如果利用上述各节所述的方法来生成一个图形,则该图形将是真正随机的。这种真正随机的图形,从本质上说,其多边形的尺寸和形状非常分散,这在某些情况下可能是不希望的。为了对生成“成核点”位置的随机性进行某种程度的控制,可以选择控制因子或“约束”,以后将该控制因子或约束称为β。该约束通过引入代表任何二个相邻成核点之间的最小距离的排斥距离E,限制相邻成核点位置的接近程度。排斥距离E按下式计算: 式中λ-成核点数密度(每单位面积上的点数)
β的范围为0~1。
为了实现“随机程度”控制,如上所述配置第一个成核点。然后选择β,从上述等式中计算E。必需注意,β和E值在整个成核点配置过程中都保持为常数。对于每个所生成的成核点坐标(x,y),计算从该点至每个已经配置的其它成核点的距离。如果对于任何一点,该距离小于E,则删去新生成的(x,y)坐标,并生成一组新坐标。这个过程重复,一直到所有N个成核点都已成功地配置为止。注意,在本发明的拼接算法中,对于所有点(x,y)(X<B),都必需相对于所有其它点检查原来的点P和复制的点P′。如果P或P′对任何其它点的接近程度超过E,则删去P和P′,并生成新的一组随机坐标(x,y)。
如果β=0,则排斥距离为零,图形为真正随机的。如果β=1,则对于六边形的封闭阵列,该排斥距离等于最接近的相邻成核点之间的距离。选择β为0~1之间的值,可以在这二个极端情况之间控制“随机程度”。
为了拼接图形,使图形的左右边缘适当地接合并使图形的上边缘和下边缘适当接合,必需在X和Y方向利用边界。
一旦将所有各成核点都计算和存储起来,就可以形成一个Delaunay三角形,作为生成最终的多边形图形的一个先导步骤。如以上在理论模型中所述那样,在这个过程中,使用一个Delaunay三角形,是从成核点,使多边形同时作为圆,迭代地“生长”的一种较简单且数学上等价的另一种选择方案。形成三角形背后的想法是,生成几组构成三角形的三个成核点的点集,使得通过这三个点作出的圆不包括该圆内其它成核点。为了形成Delaunay三角形,编写了计算机程序,将三个成核点的每一种可能的组合方式汇总起来,对每个成核点赋予一个只供辨识用的数字(整数)。然后计算通过每一组三个三角形布置的点的圆的半径和中心点坐标。将不用来确定该特定三角形的每个成核点的坐标位置,与该圆的坐标(半径和中心点)进行比较,以确定任何一个其它的成核点是否落在该三个所关注的点的圆内。如果对该三个点所构建的圆通过了测试(没有其它的成核点落入该圆内),则将该三个点的辨识数,其x和y坐标,该圆的半径和同心的x,y坐标存储起来。如果对该三个点所构建的圆没有通过测试,则不保留结果,转至对下一个三个点的集进行计算。
一旦作完了Delaunay三角形,就要进行二度空间的Voronoi棋盘形布置,以生成最终的多边形。为了进行棋盘形布置,每个留下来作为Delaunay三角形的顶点的成核点就形成多边形的中心。依次将包括该顶点的每个Delaunay三角形的外切圆的中心点按顺时针方向连接起来,就可作出该多边形的轮廓。将这些圆的中心点,按重复次序(例如顺时针方向)保留下来,就可以依次在整个成核点区域上,将每个多边形的顶点坐标存储起来。在生成多边形过程中,要进行比较,从计算中省略掉在图形边界上的三角形顶点,因为这些顶点不构成完整的多边形。
为了容易将同一图形的多个复制品拼在一起形成较大的图形,则可以将由于成核点复制在计算边界上形成的多边形作为该圆形的一部分保留下来,并与相邻图形中的相同多边形重叠,以有助于多边形间隔的匹配和对准。另一种方案是,如图3和图4所示,由成核点复制在计算边界上形成的多边形,在形成Delaunay三角形和棋盘形布置后,可以删去,以便相邻的图形可以与相适应的多边形间隔靠紧。
一旦生成了互锁的多边形二维形状的最终模型,根据本发明可利用这种互锁形状的网络作为坯料材料的一个坯料表面的结构,该图形构成了由初始平面形坯料形成的三维空心突出部分的基底形状。为了由初始材料的平面坯料构成这种突出部分,可以产生包括所要最终三维结构的照相底片的成形结构。该成形结构给上述初始材料施加适当的力,使该初始材料产生永久变形。
根据多边形顶点坐标的完整数据文件,可以进行实际输出,例如画出多边形最终图形的轮廓线。可以利用这个传统样式图形作为形成三维成形结构的金属网腐蚀过程的输入图形。如果希望多边形之间的间隔大些,则可以编写计算机程序,在每个多边形侧边上加上一条或多条平行线,以增加多边形的宽度(因此,要将多边形的尺寸减小相应的量)。
虽然示出并说明了本发明的具体实施例,但对于本领域的技术熟练人员来说,在不偏离本发明的精神和范围的条件下,可作许多改变和改进。所有这些改进都包括在所附权利要求书所确定的本发明的范围内。
Claims (10)
1.一种高速压花和粘接剂涂敷方法,所述方法包括下列步骤:
(a)将所述粘接剂涂敷在均匀加热的胶水涂敷滚筒上;
(b)将所述粘接剂涂敷在第一作有图形的压花滚筒上,该压花滚筒与具有与所述第一压花滚筒的图形互补的图形的第二作有图形的压花滚筒配合;
(c)使片材坯料以切向线速度在所述第一和第二压花滚筒之间通过,以便同时在所述坯料上压花,以及将所述粘接剂涂敷在所述坯料上,使所述粘接剂在压花凸起之间形成粘接剂图形。
2.如权利要求1所述的方法,其特征在于,它还包括下列步骤:
(a)将粘接剂涂敷在滚筒上;
(b)通过一系列在多个相邻的胶水涂敷滚筒之间的计量间隙,将所述粘接剂碾压至较小的厚度;和
(c)将所述粘接剂涂敷在所述均匀加热的胶水涂敷滚筒上。
3.如权利要求1所述的方法,其特征在于,它还包括下列步骤;
(a)将所述坯料从所述第二压花滚筒传送至所述第一压花滚筒;和
(b)从所述第一压花滚筒上剥下所述坯料。
4.如权利要求1所述的方法,其特征在于,它还包括在所述压花步骤之后冷却所述坯料的步骤。
5.如权利要求1所述的方法,其特征在于,所述粘接剂为热熔性粘接剂。
6.如权利要求1所述的方法,其特征在于,所述滚筒是加热的。
7.如权利要求1所述的方法,其特征在于,它还包括下列步骤:
(a)将粘接剂涂敷在以初始切向速度转动的滚筒上;
(b)通过在多个相邻的胶水涂敷滚筒之间的一系列的计量间隙,将所述粘接剂碾压成较小的厚度,并使所述粘接剂加速;和
(c)将所述粘接剂涂敷在以比所述初始切向速度高的切向线速度回转的所述均匀加热的胶水涂敷滚筒上。
8.如权利要求1所述的方法,其特征在于,所述粘接剂从加热的槽形模子中挤出。
9.如权利要求1所述的方法,其特征在于,所述第一作有图形的压花滚筒为阴压花滚筒,而所述第二作有图形的压花滚筒为阳压花滚筒。
10.如权利要求1所述的方法,其特征在于,所述第一作有图形的压花滚筒其上包括可除去的涂层。
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CN102658510A (zh) * | 2012-05-03 | 2012-09-12 | 上海欣展橡胶有限公司 | 一种齿形胶辊的制造工艺 |
CN104226532A (zh) * | 2013-06-11 | 2014-12-24 | 株式会社瑞光 | 热熔胶涂抹设备及热熔胶的涂抹方法 |
CN104226532B (zh) * | 2013-06-11 | 2018-05-25 | 株式会社瑞光 | 热熔胶涂抹设备及热熔胶的涂抹方法 |
CN108608786A (zh) * | 2018-05-28 | 2018-10-02 | 温州职业技术学院 | 带凸缘蜂鸣片自动压花生产线 |
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