CN1720362A - tufted laminated web - Google Patents

Abstract

A laminate web comprising first and second precursor webs, at least the first precursor web being a nonwoven web, the laminate web having a first side and a second side, the first side comprising the second precursor web and at least one discrete tuft, each discrete tuft having a linear orientation defining a longitudinal axis and comprising a plurality of tufted fibers being integral extensions of the first precursor web and extending through the second precursor web; the second side comprises the first precursor web.

Description

Translated fromChinese

簇状的层压纤维网tufted laminated web

发明领域field of invention

本发明涉及例如薄膜和纤维纺织网及无纺织网的纤维网。具体地讲，本发明涉及这些经过机械成形处理来增强柔软性或堆积性能的纤维网的层压材料。The present invention relates to fibrous webs such as films and fibrous woven and nonwoven webs. In particular, the present invention relates to laminates of these webs which have been mechanically formed to enhance softness or bulk properties.

发明背景Background of the invention

纤维网的层压材料例如薄膜和纤维网是本领域所熟知的。例如，经常将无纺织网和聚合物薄膜层压在一起以使得它们可用作一次性产品中的材料，例如一次性吸收尿布的底片。在这样的层压材料中，无纺材料部分可提供柔软性，同时薄膜部分可提供对流体的不可渗透性。Laminates of webs such as films and webs are well known in the art. For example, nonwoven webs and polymeric films are often laminated together so that they can be used as materials in disposable products, such as the backsheet of disposable absorbent diapers. In such laminates, the nonwoven portion provides softness while the film portion provides impermeability to fluids.

在许多应用中需要纤维网层压材料具有蓬松结构和/或柔软性。另外，需要纤维网层压材料在纤维网的两侧具有不同的纹理和柔软性。也就是说，纤维网在一侧可具有有纹理的、相对粗糙的表面，而在另一侧可具有柔软的、相对光滑的表面。这可以通过将两个相异的纤维网层压在一起来实现，例如通过粘合剂或热结合的方法。例如，簇状的无纺织网可用粘合剂粘附到非簇状的无纺织网上以制成具有两个完全不同纹理和柔软特征的侧面的层压纤维网。Lofty structure and/or softness are desired in fiber web laminates in many applications. Additionally, web laminates are required to have different textures and softness on both sides of the web. That is, the web can have a textured, relatively rough surface on one side and a soft, relatively smooth surface on the other side. This can be achieved by laminating two dissimilar webs together, for example by adhesive or thermal bonding. For example, a tufted nonwoven web can be adhered with an adhesive to a non-tufted nonwoven web to produce a laminated web having two sides with distinct texture and softness characteristics.

此外，已知可将两种无纺材料结合到一种层压材料中以便在单一层压纤维网中得到相异材料的有益效果。例如，已知用针刺无纺织网来生产整体粘合和缠结的无纺织网。该方法经常被简称为“针刺”。例如，1992年1月14日授予Guthrie的美国专利5,080,951公开了一种通过针刺方法结合的多个层构成的无纺织网，所述针刺方法使一些纤维延伸穿过整个织物的厚度并且超出表面，从而留下从纤维网的外表面突出的短段长丝。用频繁地水缠绕来实现两个纤维无纺织网的类似缠结。针刺，类似于流体缠结，是一种用于制造无纺织网、尤其是打算用于一次性制品的纤维网的相对较慢且昂贵的方法。Furthermore, it is known that two nonwoven materials can be combined into one laminate to obtain the benefits of dissimilar materials in a single laminate web. For example, it is known to produce integrally bonded and entangled nonwoven webs by needling nonwoven webs. This method is often referred to simply as "acupuncture". For example, U.S. Patent 5,080,951 issued to Guthrie on January 14, 1992 discloses a nonwoven web composed of multiple layers bonded by a needling process that extends some of the fibers through the thickness of the fabric and beyond. surface, thereby leaving short segments of filaments protruding from the outer surface of the web. Similar entanglement of the two fibrous nonwoven webs is achieved with frequent hydroentanglement. Needling, similar to fluid entanglement, is a relatively slow and expensive method for making nonwoven webs, especially webs intended for disposable articles.

一般而言，用于制造在其至少一个面上具有蓬松或簇状结构的薄膜和纤维网的层压材料的目前方法对这些纤维网的许多用途来说相对昂贵，或由于使用粘合剂或热结合使所得的纤维网太硬。In general, current methods for making laminates of films and webs having a lofted or tufted structure on at least one face thereof are relatively expensive for many uses of these webs, either due to the use of adhesives or Thermal bonding makes the resulting web too rigid.

因此，需要一种具有毛巾布状性能的低成本层压纤维网。Accordingly, there is a need for a low cost laminated web having terry-like properties.

此外，还需要一种层压纤维网，在这种层压纤维网中无纺材料具有簇状区域，并且薄膜或另一种无纺材料层能够优选通过不需要粘合剂或热结合的方法接合以保持层压结构。In addition, there is a need for a laminated web in which the nonwoven material has tufted regions and a film or another nonwoven layer can be bonded, preferably by a method that does not require adhesives or heat. Bonded to maintain laminate structure.

此外，还需要一种层压纤维网，在这种层压纤维网中，各层不但被接合而且彼此贯穿成为一体。In addition, there is a need for a laminated web in which the layers are not only joined but also integrated throughout each other.

此外，还需要一种可相对廉价地制造具有毛巾布状性能的层压纤维网的方法。Furthermore, there is a need for a relatively inexpensive method of making laminated webs having terry-like properties.

此外，还需要一种制造薄膜、纺织材料和/或无纺材料的柔软、高堆积体积的多孔层压纤维网的低成本方法。Furthermore, there is a need for a low cost method of making soft, high bulk porous laminate webs of films, woven materials and/or nonwoven materials.

发明概述Summary of the invention

包括第一和第二前体纤维网的层压纤维网，至少所述第一前体纤维网为无纺织网，所述层压纤维网具有第一侧面和第二侧面，第一侧面包括第二前体纤维网和至少一个离散的毛簇，每一离散毛簇具有限定纵向轴线的线性定向并包括多个作为第一前体纤维网的整体伸出部且延伸穿过第二前体纤维网的簇状纤维；第二侧面包括所述第一前体纤维网。A laminate web comprising first and second precursor webs, at least the first precursor web being a nonwoven web, the laminate web having a first side and a second side, the first side comprising a first Two precursor webs and at least one discrete tuft, each discrete tuft having a linear orientation defining a longitudinal axis and comprising a plurality of integral protrusions being the first precursor web and extending through the second precursor fibers tufted fibers of the web; the second side comprising said first precursor web.

附图说明Description of drawings

图1是本发明纤维网的透视图。Figure 1 is a perspective view of a web of the present invention.

图2为图1所示纤维网的一部分的放大视图。Figure 2 is an enlarged view of a portion of the web shown in Figure 1 .

图3为图2的3-3截面的剖面图。FIG. 3 is a cross-sectional view of section 3-3 in FIG. 2 .

图4为图3中4-4所示纤维网的一部分的平面图。FIG. 4 is a plan view of a portion of the web shown at 4-4 in FIG. 3. FIG.

图5为用于形成本发明纤维网的装置的透视图。Figure 5 is a perspective view of an apparatus for forming a web of the present invention.

图6为图5所示装置的一部分的横截面图。FIG. 6 is a cross-sectional view of a portion of the device shown in FIG. 5 .

图7是用于形成本发明纤维网的一个实施方案的装置的一部分的透视图。Figure 7 is a perspective view of a portion of an apparatus for forming an embodiment of a web of the present invention.

图8是用于形成本发明纤维网的装置的一部分的放大透视图。Figure 8 is an enlarged perspective view of a portion of an apparatus for forming a web of the present invention.

图9为本发明纤维网的另一实施方案的一部分的放大视图。Figure 9 is an enlarged view of a portion of another embodiment of a web of the present invention.

图10为本发明的卫生巾部分切除的平面图。Figure 10 is a partially cut away plan view of the sanitary napkin of the present invention.

图11为本发明的卫生棉塞部分切除的透视图。Figure 11 is a partially cut away perspective view of the tampon of the present invention.

图12至15为本发明纤维网的显微照片。Figures 12 to 15 are photomicrographs of webs of the present invention.

发明的详细描述Detailed description of the invention

图1表示本发明的层压纤维网1，以下简称为纤维网1。纤维网1包括至少两层。所述各层在本文指一般为平面、二维的前体纤维网，如第一前体纤维网20和第二前体纤维网21。任何一个前体纤维网均可为薄膜、无纺材料或纺织纤维网。前体纤维网20和21(以及任何附加纤维网)可通过粘合剂、热结合、超声结合等进行接合，但优选不使用粘合剂或其它粘合形式进行接合。如下所公开的，纤维网1的组成前体纤维网可通过由毛簇6的形成而产生的互锁机械啮合进行接合。FIG. 1 shows a laminated web 1 of the present invention, hereinafter simply referred to as web 1 . The fiber web 1 comprises at least two layers. The layers are referred to herein as generally planar, two-dimensional precursor webs, such asfirst precursor web 20 andsecond precursor web 21 . Any one of the precursor webs can be a film, a nonwoven material, or a woven web.Precursor webs 20 and 21 (and any additional webs) may be joined by adhesives, thermal bonds, ultrasonic bonds, etc., but preferably are joined without the use of adhesives or other forms of bonding. As disclosed below, the constituent precursor webs of web 1 may be joined by interlocking mechanical engagement resulting from the formation oftufts 6 .

纤维网1具有第一侧面3和第二侧面5，术语“侧面”用在一般为平面的二维纤维网(如当处于通常平放状态时具有两个侧面的纸和薄膜)的常见用法中。每一前体纤维网20和21均分别具有第一表面12和13，并分别具有第二表面14和15(如图3中所示)。纤维网1具有如纤维网制造领域通常所知的纵向(MD)和横向(CD)。尽管本发明可以用聚合物薄膜和机织纤维网来实施，但在优选的实施方案中第一前体纤维网20为由基本无规定向纤维构成的无纺织网。“基本无规定向”是指由于所述前体纤维网的加工条件，可能MD(纵向)取向纤维的量高于CD(横向)取向纤维的量，反之亦然。例如，在纺粘和熔喷处理中连续股纤维被沉积在纵向移动的支撑上。尽管试图让纺粘或熔喷无纺织网的纤维取向真正“随机”，但通常纵向取向纤维的百分比与横向的相比要稍高。在一个优选的实施方案中，第二前体纤维网21是类似于第一前体纤维网20的无纺织网，或是聚合物薄膜或者开孔聚合物薄膜，如聚乙烯薄膜。The web 1 has afirst side 3 and asecond side 5, and the term "side" is used in common usage for two-dimensional webs that are generally planar, such as paper and films that have two sides when in a generally lay-flat condition. . Eachprecursor web 20 and 21 has afirst surface 12 and 13, respectively, and a second surface 14 and 15, respectively (as shown in FIG. 3). The web 1 has a machine direction (MD) and a cross direction (CD) as generally known in the art of web manufacturing. Although the present invention can be practiced with polymeric films and woven webs, in a preferred embodimentfirst precursor web 20 is a nonwoven web composed of substantially randomly oriented fibers. By "substantially random orientation" is meant that due to the processing conditions of the precursor web, it is possible that the amount of MD (machine direction) oriented fibers is higher than the amount of CD (cross direction) oriented fibers and vice versa. For example, in spunbond and meltblown processes continuous strands of fibers are deposited on a longitudinally moving support. Although attempts are made to make the fiber orientation of spunbond or meltblown nonwoven webs truly "random," generally the percentage of fibers oriented in the machine direction is slightly higher compared to the cross direction. In a preferred embodiment,second precursor web 21 is a nonwoven web similar tofirst precursor web 20, or a polymeric film or an apertured polymeric film, such as a polyethylene film.

在一个实施方案中，纤维网1的第一侧面3是由第二前体纤维网21的第一表面13的外露部分和至少一个、但优选多个离散毛簇6所限定，该离散毛簇为无纺第一前体纤维网20的纤维的整体伸出部分。如图3所示，每个毛簇6均可包括多个延伸穿过第二前体纤维网21并且由它们的第一表面13向外的环状、对齐的纤维8。在另一个实施方案中，每个毛簇6均可包括多个从第一表面13向外延伸的非环状纤维18(如图3所示)。In one embodiment, thefirst side 3 of the web 1 is defined by the exposed portion of thefirst surface 13 of thesecond precursor web 21 and at least one, but preferably a plurality ofdiscrete tufts 6, the discrete tufts is an integral extension of the fibers of the nonwovenfirst precursor web 20 . As shown in FIG. 3 , eachtuft 6 may comprise a plurality of annular, aligned fibers 8 extending through thesecond precursor web 21 and outwardly from theirfirst surface 13 . In another embodiment, eachtuft 6 may include a plurality of non-circular fibers 18 extending outwardly from the first surface 13 (as shown in FIG. 3 ).

本文所用术语“无纺织网”指具有相互交错但并无机织或编织织物中那样的重复图案的独立纤维或丝线结构的纤维网，所述机织或编织织物典型地不具有无规定向纤维。无纺织网或织物已形成于多种方法，例如熔喷法、纺粘法、水缠绕法、气流成网和粘合粗梳纤维网法，包括粗梳热结合。无纺织物的定量通常用克每平方米(gsm)表示。层压纤维网的定量是各组成层和任何其它附加部件的组合定量。纤维直径通常用微米表示；纤维尺寸也可以用旦表示，它是每纤维长度重量的单位。适用于本发明的层压纤维网的定量可为10gsm至500gsm，其取决于纤维网1的最终用途。例如，对于用作手巾，第一前体纤维网20和第二前体纤维网21都可以是定量在25gsm和100gsm之间的无纺织网。对于用作浴巾，第一前体纤维网20和第二前体纤维网21都可具有125gsm和250gsm之间的定量。对于用作地膜，如防腐衬里，层压材料的定量在350gsm和500gsm之间或更高可能是合适的。As used herein, the term "nonwoven web" refers to a web having a structure of individual fibers or threads that are interlaced but not in a repeating pattern as in a woven or woven fabric, which typically does not have randomly oriented fibers. Nonwoven webs or fabrics have been formed in a variety of processes, such as meltblowing, spunbonding, hydroentanglement, airlaying, and bonded carded web processes, including carded thermal bonding. The basis weight of nonwoven fabrics is usually expressed in grams per square meter (gsm). The basis weight of a laminate web is the combined basis weight of the individual constituent layers and any other additional components. Fiber diameter is usually expressed in microns; fiber size can also be expressed in denier, which is a unit of weight per fiber length. The basis weight of laminated webs suitable for use in the present invention can range from 10 gsm to 500 gsm, depending on the end use of the web 1 . For example, for use as towels, bothfirst precursor web 20 andsecond precursor web 21 may be nonwoven webs having a basis weight between 25 gsm and 100 gsm. For use as bath towels, bothfirst precursor web 20 andsecond precursor web 21 may have a basis weight of between 125 gsm and 250 gsm. For use as a mulch, such as an anti-corrosion liner, a laminate basis weight between 350gsm and 500gsm or higher may be suitable.

无纺前体纤维网20或21的组成纤维可以由聚合物构成，例如聚乙烯、聚丙烯、聚酯以及它们的共混物。所述纤维可包含纤维素、人造丝、棉线、或其它天然材料或聚合物与天然材料的共混物。纤维也可包含超吸收材料，如聚丙烯酸酯或合适材料的任何组合。纤维可以是单组分、双组分、和/或双成分、非圆形的(例如，毛细管道纤维)，并且可具有的主横截面尺寸(例如，圆纤维的直径)为0.1微米至500微米。例如，一种适用于无纺织网的纤维包括纳米纤维。纳米纤维被描述为平均直径小于1微米的纤维。纳米纤维可包括无纺织网中的所有纤维或无纺织网中的部分纤维。无纺前体纤维网的组成纤维也可以是不同纤维类型的混合物，这些不同纤维类型在如化学(例如PE和PP)、组分(单-和双-)、旦(微旦和＞20旦)、形状(即毛细管和圆形)等这样一些特征上不相同。组成纤维的范围可以为约0.1旦至约100旦。The constituent fibers ofnonwoven precursor web 20 or 21 may be composed of polymers such as polyethylene, polypropylene, polyester, and blends thereof. The fibers may comprise cellulose, rayon, cotton, or other natural materials or blends of polymers and natural materials. The fibers may also comprise superabsorbent material such as polyacrylate or any combination of suitable materials. Fibers can be monocomponent, bicomponent, and/or bicomponent, non-circular (e.g., capillary channel fibers), and can have a major cross-sectional dimension (e.g., diameter of a round fiber) from 0.1 microns to 500 Micron. For example, one type of fiber suitable for use in nonwoven webs includes nanofibers. Nanofibers are described as fibers having an average diameter of less than 1 micron. Nanofibers can include all of the fibers in the nonwoven web or some of the fibers in the nonwoven web. The constituent fibers of the nonwoven precursor web can also be a mixture of different fiber types such as chemical (e.g., PE and PP), component (mono- and bi-), denier (microdenier and >20 denier) ), shape (ie, capillary and circular), etc., are different in some features. The constituent fibers may range from about 0.1 denier to about 100 denier.

本文所用“纺粘纤维”是指以如下方法形成的小直径的纤维：将熔融的热塑性材料从喷丝头的多个精细的且通常为圆形的毛细管挤出成为长丝，然后将挤出的长丝直径快速减小。当纺粘纤维被沉积到收集面上时通常不发粘。纺粘纤维通常为连续的且具有的平均直径(来自至少10个的样本)大于7微米，更具体地讲，在约10微米和40微米之间。"Spunbond fibers" as used herein refers to small diameter fibers formed by extruding molten thermoplastic material into filaments from a plurality of fine, generally circular capillaries of a spinneret, The filament diameter decreases rapidly. Spunbond fibers are generally not tacky when deposited onto a collecting surface. Spunbond fibers are generally continuous and have an average diameter (from a sample of at least 10) greater than 7 microns, more specifically, between about 10 microns and 40 microns.

本文所用术语“熔喷法”是指如下形成纤维的方法：将熔融的热塑性材料通过多个精细的且通常为圆形的冲模毛细管挤出成为熔融丝线或长丝，然后进入通常加热的会聚高速气体(如空气)流使熔融热塑性材料的长丝削弱，以使其直径变细，甚至可以小到微纤维直径。其后，熔喷纤维仍然发粘时由高速气流运载并沉积于收集表面上，形成无规分布的熔喷纤维的纤维网。熔喷纤维是连续的或不连续的微纤维，并且通常平均直径小于10微米。The term "meltblowing" as used herein refers to a method of forming fibers by extruding molten thermoplastic material through a plurality of fine and usually circular die capillaries into molten threads or filaments, and then into a converging, usually heated, high-speed A stream of gas (such as air) weakens the filaments of molten thermoplastic material so that they become thinner in diameter, even down to microfiber diameters. Thereafter, the meltblown fibers, while still tacky, are carried by the high velocity air stream and deposited on a collecting surface to form a web of randomly distributed meltblown fibers. Meltblown fibers are continuous or discontinuous microfibers and typically have an average diameter of less than 10 microns.

本文所用术语“聚合物”通常包括但不限于均聚物、共聚物，例如嵌段、接枝、无规及交替共聚物、三元共聚物等，以及它们的共混物和改性物。此外，除非另有具体限定，术语“聚合物”包括所述材料的所有可能的几何构形。所述构形包括，但不限于，全同立构、无规立构、间同立构以及随机对称。The term "polymer" as used herein generally includes, but is not limited to, homopolymers, copolymers, such as block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless specifically defined otherwise, the term "polymer" includes all possible geometries of the material in question. Such configurations include, but are not limited to, isotactic, atactic, syndiotactic, and random symmetries.

本文所用术语“单组分”纤维是指仅使用一种聚合物由一个或多个挤出机成形的纤维。这并不意味着排除由一种聚合物形成的、其中添加少量添加剂用于染色、抗静电特性、润滑、亲水性等的纤维。这些添加剂，例如用来染色的二氧化钛，通常以小于约5％重量且更典型约2％重量的含量存在。As used herein, the term "monocomponent" fibers refers to fibers formed from one or more extruders using only one type of polymer. This is not meant to exclude fibers formed from one polymer to which small amounts of additives are added for dyeing, antistatic properties, lubricity, hydrophilicity, etc. These additives, such as titanium dioxide for dyeing, are generally present at levels of less than about 5% by weight and more typically about 2% by weight.

本文所用术语“双组分纤维”是指由至少两种不同的聚合物从各自的挤出机挤出但纺在一起形成一根纤维的纤维。双组分纤维有时也称作共轭纤维或多组分纤维。所述聚合物被排列在基本定位不变的截然不同的区域中，这些区域与双组分纤维的横截面交叉且沿着双组分纤维的长度连续地延伸。例如，这种双组分纤维的构型可以是鞘/芯型排列，其中一种聚合物被另一种聚合物围绕，或者是并列型排列、饼式排列或“天星状”排列。As used herein, the term "bicomponent fiber" refers to a fiber of at least two different polymers extruded from separate extruders but spun together to form a single fiber. Bicomponent fibers are also sometimes referred to as conjugate fibers or multicomponent fibers. The polymers are arranged in substantially invariantly positioned distinct regions that intersect the cross-section of the bicomponent fiber and extend continuously along the length of the bicomponent fiber. For example, the configuration of such bicomponent fibers can be a sheath/core arrangement in which one polymer is surrounded by another, or a side-by-side arrangement, a pie arrangement, or a "star-like" arrangement.

本文所用术语“双成分纤维”是指由同一个挤出机挤出作为共混物的至少两种聚合物形成的纤维。双成分纤维不具有被排列在基本定位不变的、与纤维横截面交叉的截然不同区域中的各种聚合物组分，并且各种聚合物沿着纤维的整个长度通常不是连续的，而是通常为随机开始和结束的成形原纤。双成分纤维有时也指多组分纤维。As used herein, the term "bicomponent fiber" refers to a fiber formed from the same extruder extruding at least two polymers as a blend. Biconstituent fibers do not have the various polymer components arranged in distinct regions across the cross-section of the fiber that are substantially invariantly positioned, and the various polymers are generally not continuous along the entire length of the fiber, but rather Typically shaped fibrils that start and end randomly. Bicomponent fibers are also sometimes referred to as multicomponent fibers.

本文所用术语“非圆形纤维”是描述具有非圆形横截面的纤维，且包括“成形纤维”和“毛细管道纤维”。这样的纤维可以是实心的或中空的，并且它们可以是三叶形、△形，并且优选是其外表面具有毛细管道的纤维。毛细管道可以是各种横截面形状，如“U形”、“H形”、“C形”、“V形”。一个优选的毛细管道纤维为T-401，命名为4DG纤维，购自TN，Johnson City的Fiber InnovationTechnologies。T-401纤维为聚对苯二甲酸乙二醇酯(PET聚酯)。The term "non-circular fiber" as used herein is used to describe fibers having a non-circular cross-section, and includes "shaped fibers" and "capillary channel fibers". Such fibers may be solid or hollow, and they may be trilobal, delta-shaped, and are preferably fibers having capillary channels on their outer surface. Capillary channels can be of various cross-sectional shapes such as "U-shaped", "H-shaped", "C-shaped", "V-shaped". A preferred capillary channel fiber is T-401, designated 4DG fiber, available from Fiber Innovation Technologies of Johnson City, TN. T-401 fiber is polyethylene terephthalate (PET polyester).

本文所用术语“整体”(如用于毛簇6的“整体伸出部”中)是指毛簇6的纤维起源自第一前体纤维网20的纤维。因此，毛簇6的环状纤维8和非环状纤维18可以是第一前体纤维网20的塑性变形并伸出的纤维，并且因此和第一前体纤维网20成为一体。本文所用“整体”是用来区别于为了制造毛簇而引入或加入到分离的前体纤维网中的纤维，例如，在常规地毯制造中通常所做的。The term "integral" (as used in "integral extensions" of tufts 6 ) as used herein means that the fibers oftufts 6 originate from the fibers offirst precursor web 20 . Thus, the annular fibers 8 and the non-annular fibers 18 of thetufts 6 may be plastically deformed and protruding fibers of thefirst precursor web 20 and thus integral with thefirst precursor web 20 . "Integral" as used herein is to be distinguished from fibers that are introduced or added to a separate precursor web for the purpose of making tufts, for example, as is commonly done in conventional carpet manufacturing.

毛簇6的数量、间距和尺寸可改变以为纤维网1的第一侧面3提供变化的纹理。例如，如果毛簇6有充分靠近的间距，纤维网1的第一侧面3可具有毛巾布状织物的感觉。可供选择地，毛簇6可以如直线形或填充形的图案排列以造成层压纤维网的一部分具有较强的纹理、柔软性、堆积体积、吸收性或视觉图案吸引力。例如，当毛簇6以直线或细纹图案排列时，毛簇可具有刺绣的外观。毛簇6也可以排列形成特定的形状，例如花样、字母或徽标。例如，这些形状可被用于旅馆浴巾或浴衣所用的层压材料上，在其上面可具有旅馆的名称或徽标。同样地，单个毛簇6的尺寸大小，如高度、长度和宽度也可改变。单个毛簇可以长约3cm，并且可以单独制造或分散在各种尺寸的毛簇之中。The number, spacing and size of thetufts 6 can be varied to provide varying textures to thefirst side 3 of the web 1 . For example, if thetufts 6 are sufficiently closely spaced, thefirst side 3 of the web 1 may have the feel of a terry cloth. Alternatively, thetufts 6 may be arranged in a pattern such as a linear or filled pattern to impart greater texture, softness, bulk, absorbency or visual pattern appeal to a portion of the laminate web. For example, when thetufts 6 are arranged in a straight or fine pattern, the tufts may have the appearance of embroidery. Thehair tufts 6 can also be arranged to form specific shapes, such as patterns, letters or logos. For example, these shapes could be used on laminated material for hotel bath towels or bathrobes, which could have the hotel's name or logo on it. Likewise, the dimensions ofindividual tufts 6, such as height, length and width, may also vary. A single tuft can be about 3 cm long and can be made individually or dispersed among tufts of various sizes.

第一前体纤维网20可以是纤维纺织网或无纺织网，其包括的纤维具有足够伸长特性以使其一部分形成如下面更全面描述的毛簇6。毛簇通过纤维在第一前体纤维网20离散的局部部分处在Z方向被推出平面外而形成。推出平面外是由于纤维的位移，即纤维能够相对于其它纤维运动并可以说被拉出平面外。然而，对大多数无纺第一前体纤维网20更常见的是，推出平面外是由于毛簇6的纤维至少被部分塑性拉伸并永久变形形成毛簇6。因此，在一个实施方案中，根据所需毛簇6的高度，无纺第一前体纤维网20的组成纤维可显示具有的断裂伸长率为至少约5％，更优选至少约10％，更优选至少约25％，更优选至少约50％，且更优选至少约100％。断裂伸长率可由简单的张力测试来测定，例如采用Instron张力测试仪，并且通常可以在这些纤维或纤维网的供应商提供的材料数据表中找到。Thefirst precursor web 20 may be a fibrous woven or nonwoven web comprising fibers having sufficient elongation properties such that a portion thereof formstufts 6 as described more fully below. The tufts are formed by fibers being pushed out of plane in the Z direction at discrete localized portions of thefirst precursor web 20 . Pushing out of plane is due to the displacement of the fibers, ie fibers are able to move relative to other fibers and be pulled out of plane, so to speak. However, more commonly for most nonwovenfirst precursor webs 20, the push out of plane is due to the fibers oftufts 6 being at least partially plastically stretched and permanently deformed to formtufts 6. Thus, in one embodiment, the constituent fibers of the nonwovenfirst precursor web 20 may exhibit an elongation at break of at least about 5%, more preferably at least about 10%, depending on the desiredtuft 6 height, More preferably at least about 25%, more preferably at least about 50%, and more preferably at least about 100%. Elongation at break can be determined by a simple tensile test, for example using an Instron Tensile Tester, and can usually be found on the material data sheets provided by the suppliers of these fibers or webs.

应当理解的是，合适的无纺第一前体纤维网20应包括能够经受足够塑性变形和拉伸伸长、或具有足够的纤维移动性的纤维，从而可形成环状纤维8。然而，人们认识到被推出第一前体纤维网20的第一表面12的平面外的一定百分比的纤维将不形成环，而代之的是断裂并形成松散的末端。这些纤维在本文被称为“松散”纤维或如图3所示的“松散纤维末端”18。松散纤维末端18对于本发明未必是不可取的，并且在一些实施方案中，毛簇6的大多数或全部纤维可以是松散纤维末端18。松散纤维末端18也可以是由短人造短纤维组成或包含短人造短纤维的无纺织网来形成毛簇6的结果。在这种情况下，一些人造短纤维末端可能突出到毛簇6之中，这取决于如纤维网中人造短纤维的数量、人造短纤维切割长度、以及毛簇的高度等这些情况。在一些实施例中，可能需要在前体纤维网中使用不同长度纤维的共混物或者在不同的层中使用不同长度纤维的共混物。这样能够选择性地将长纤维与短纤维分开。长纤维可主要形成毛簇6，而短纤维主要保留在未形成毛簇6的纤维网部分。一个示例性纤维长度的混合物可包括大约为2至8厘米的长纤维和小于约1厘米的短纤维的纤维。It should be understood that a suitable nonwovenfirst precursor web 20 will comprise fibers capable of undergoing sufficient plastic deformation and tensile elongation, or having sufficient fiber mobility, such that endless fibers 8 can be formed. However, it is recognized that a certain percentage of fibers pushed out of the plane of the first surface 12 of thefirst precursor web 20 will not form loops, but instead break and form loose ends. These fibers are referred to herein as "loose" fibers or "loose fiber ends" 18 as shown in FIG. 3 . Loose fiber ends 18 are not necessarily undesirable for the present invention, and in some embodiments, most or all of the fibers oftuft 6 may be loose fiber ends 18 . The loose fiber ends 18 may also be composed of or the result of a nonwoven web comprising short staple fibers to form thetufts 6 . In this case, some of the staple fiber ends may protrude into thetufts 6, depending on such factors as the amount of staple fibers in the web, the cut length of the staple fibers, and the height of the tufts. In some embodiments, it may be desirable to use a blend of fibers of different lengths in the precursor web or to use a blend of fibers of different lengths in different layers. This enables selective separation of long fibers from short fibers. Long fibers may mainly formtufts 6, while short fibers mainly remain in the portion of the web wheretufts 6 are not formed. An exemplary mixture of fiber lengths may include fibers of about 2 to 8 centimeters long fibers and less than about 1 centimeter short fibers.

第一前体纤维网20可以是包含弹性纤维或弹性体纤维的纤维纺织网或无纺织网。弹性纤维或弹性体纤维可以被拉伸其原始尺寸的至少约50％并且可以恢复到其原始尺寸的10％以内。如果在无纺材料中由于纤维的移动性，纤维被简单置换，或如果纤维被拉伸超过它们的弹性极限并塑性变形，毛簇6可以由弹性纤维形成。Thefirst precursor web 20 may be a fibrous woven or nonwoven web comprising elastic or elastomeric fibers. An elastic or elastomeric fiber can be stretched at least about 50% of its original dimension and can return to within 10% of its original dimension. Thetufts 6 may be formed from elastic fibers if the fibers are simply displaced in the nonwoven material due to their mobility, or if the fibers are stretched beyond their elastic limit and deformed plastically.

第二前体纤维网21事实上可以是任何纤维网材料，唯一的要求是它应具有足够的完整性以便通过下面所述的方法被成形在层压材料中，并且相对于第一前体纤维网20它应具有足够小的伸长特性，以使得在经受来自第一前体纤维网20在第二前体纤维网21的方向上被推出平面外的纤维应变时，第二前体纤维网21将破裂，例如，由于伸长破坏被撕裂，这样使得第一前体纤维网20的一部分能够伸出(即，所谓的“穿过”)第二前体纤维网21以在纤维网1的第一侧面3上形成毛簇6。在一个实施方案中，第二前体纤维网21为聚合物薄膜。第二前体纤维网21也可以为机织纺织纤维网、无纺织网、聚合物薄膜、开孔聚合物薄膜、纸幅(例如，薄页纸)、金属箔(例如，铝包装箔)、泡沫(例如，尿烷泡沫板)等。Thesecond precursor web 21 can be virtually any web material, the only requirement being that it should have sufficient integrity to be formed into a laminate by the method described below and relative to the first precursor fibers Theweb 20 should have sufficiently small elongation properties so that when subjected to fiber strain from thefirst precursor web 20 being pushed out of plane in the direction of thesecond precursor web 21, thesecond precursor web 21 will rupture, e.g., be torn due to elongational failure, such that a portion of thefirst precursor web 20 can protrude (i.e., so-called "pass through") thesecond precursor web 21 to formTufts 6 are formed on thefirst side 3. In one embodiment,second precursor web 21 is a polymeric film. Thesecond precursor web 21 can also be a woven textile web, a nonwoven web, a polymer film, an apertured polymer film, a paper web (e.g., tissue paper), a metal foil (e.g., aluminum packaging foil), Foam (eg, urethane foam board) and the like.

图1所示的纤维网1的实施方案的典型毛簇6示在图2的进一步放大视图中。如图2或3所示，毛簇6包括多个环状纤维8，所述环状纤维基本上对齐以使毛簇6具有明显的线性定向和纵向轴线L。毛簇6还具有通常在MD-CD平面内正交于纵向轴线L的横向轴线T。在如图1和2所示的实施方案中，纵向轴线L平行于MD。在一个实施方案中，所有间隔开的毛簇6通常都具有平行的纵向轴线L。每单位面积纤维网1的毛簇6数，即毛簇6的面积密度，可以从每单位面积例如每平方厘米1簇变化到高达每平方厘米100簇。每平方厘米可有至少10个、或至少20个毛簇6，这决定于最终用途。通常，在纤维网1的整个面积内面积密度不要求为一致的，但毛簇6只能在纤维网1的某些区域内存在，例如在具有预定形状，如线形、条形、带形、圆形等的区域。Typical tufts 6 of the embodiment of the web 1 shown in FIG. 1 are shown in a further enlarged view in FIG. 2 . As shown in Figures 2 or 3, thetufts 6 comprise a plurality of annular fibers 8 substantially aligned so that thetufts 6 have a substantially linear orientation and longitudinal axis L. As shown in FIG. Thetufts 6 also have a transverse axis T which is normal to the longitudinal axis L generally in the MD-CD plane. In the embodiment shown in Figures 1 and 2, the longitudinal axis L is parallel to the MD. In one embodiment, all spaced aparttufts 6 have generally parallel longitudinal axes L. The number oftufts 6 per unit area of web 1, ie the areal density oftufts 6, can vary from 1 tuft per unit area, for example, up to 100 tufts per square centimeter. There may be at least 10, or at least 20tufts 6 per square centimeter, depending on the end use. Generally, the area density is not required to be consistent in the entire area of the fiber web 1, but thetufts 6 can only exist in some areas of the fiber web 1, for example, in a predetermined shape, such as linear, strip, ribbon, area such as a circle.

通过本文说明应当理解，在纤维网1的许多实施方案中，第二前体纤维网21的开口4将具有明显的线性定向和纵向轴线，该开口被定向为平行于它对应的毛簇6的纵向轴线L。同样地，开口4也将具有在MD-CD平面内通常正交于纵向轴线的横向轴线。It should be understood from the description herein that in many embodiments of the web 1, the openings 4 of thesecond precursor web 21 will have a substantially linear orientation and a longitudinal axis that is oriented parallel to the openings of its correspondingtufts 6. longitudinal axis L. Likewise, the opening 4 will also have a transverse axis generally normal to the longitudinal axis in the MD-CD plane.

如图1至4所示，毛簇6延伸穿过第二前体纤维网21中的开口4。开口4按照下面详述的方法经局部破裂第二前体纤维网21而形成。破裂可涉及第二前体纤维网21的简单裂开，使得开口4留下简单的二维孔。然而，对某些材料如聚合物薄膜而言，部分第二前体纤维网21可以被偏转或推出平面(即，第二前体纤维网21的平面)外形成折翼状的结构，本文称为翼片7。翼片7的形状和结构高度依赖于第二前体纤维网21的材料性能。翼片7可具有一个或多个翼片的普通结构，如图1和2所示。在其它的实施方案中，翼片7可具有更象火山状的结构，好像毛簇6从翼片7喷发出来。As shown in FIGS. 1 to 4 , thetufts 6 extend through the openings 4 in thesecond precursor web 21 . Openings 4 are formed by partially disruptingsecond precursor web 21 as detailed below. Fracture may involve simple cleavage ofsecond precursor web 21 such that openings 4 leave simple two-dimensional holes. However, for certain materials such as polymeric films, portions of thesecond precursor web 21 may be deflected or pushed out of plane (i.e., the plane of the second precursor web 21) to form flap-like structures, referred to herein as Wing 7. The shape and structure of the flap 7 is highly dependent on the material properties of thesecond precursor web 21 . The fins 7 may have the general configuration of one or more fins, as shown in FIGS. 1 and 2 . In other embodiments, the fins 7 may have a more volcano-like structure, as if thetufts 6 erupted from the fins 7 .

在一个实施方案中，翼片7不显著贡献毛簇6的材料，并且尤其是对毛簇6的触觉品质没有显著贡献。因此，在一个实施方案中层压纤维网1包括至少两层(即，前体纤维网20和21)，但至少其中一层(即，图1至4中的前体纤维网21)对毛簇6的触觉品质不产生显著影响。In one embodiment, the flaps 7 do not contribute significantly to the material of thetufts 6 and in particular to the tactile quality of thetufts 6 . Thus, in one embodiment laminate web 1 includes at least two layers (i.e.,precursor webs 20 and 21), but at least one of the layers (i.e.,precursor web 21 in FIGS. The tactile quality of 6 is not significantly affected.

在一个实施方案中，翼片7可显著伸出平面外，甚至可以说和毛簇6本身一样高。在此实施方案中，翼片7可导致毛簇6更加有弹力和更加不容易由于压缩或弯曲力的作用而变平。因此，在一个实施方案中，层压纤维网1包括至少两层(即，前体纤维网20和21)，并且两层都影响毛簇6的触觉品质。In one embodiment, the flaps 7 can protrude significantly out of plane, even as high as thetufts 6 themselves. In this embodiment, the tabs 7 cause thetufts 6 to be more resilient and less prone to flattening due to compressive or bending forces. Thus, in one embodiment, laminate web 1 includes at least two layers (ie,precursor webs 20 and 21 ), and both layers affect the tactile quality oftufts 6 .

毛簇6在某种意义上“穿过”第二前体纤维网21且通过与开口4的摩擦接合被“锁定”在适当的位置。例如，在某些实施方案中，开口4的横向宽度(即，平行于其横向轴线测量的尺寸)可以小于形成开口(经下面所述的方法)的齿的最大宽度。这表示在开口处一定量的恢复趋于限制毛簇6向外经由开口4被拉回。毛簇与开口4的摩擦啮合提供了无需粘合剂或热结合而形成的在一个侧面具有永久毛簇的层压纤维网结构。Thetufts 6 "pass through" thesecond precursor web 21 in a sense and are "locked" in place by frictional engagement with the openings 4 . For example, in certain embodiments, the transverse width (ie, the dimension measured parallel to its transverse axis) of the opening 4 may be less than the maximum width of the tooth forming the opening (via the method described below). This means that a certain amount of recovery at the opening tends to limittufts 6 being pulled back outwards through the opening 4 . The frictional engagement of the tufts with the openings 4 provides a laminated web structure with permanent tufts on one side without the need for adhesives or thermal bonding.

由于在某些实施方案中至少其中一层(例如，图1至4中相对较低伸长率的聚合物薄膜或薄页纸第二前体纤维网21)不为毛簇6显著贡献材料(例如在图1至4所示的实施方案中)，包含无纺第一前体纤维网20的纤维网1的特征可在于在纤维网1的两个侧面上用仅由无纺第一前体纤维网20贡献的纤维作为主要纤维。因此，毛簇6可以被间隔得足够近以使其有效覆盖纤维网1的第一侧面3。在这样一个实施方案中，纤维网1的两个侧面体都看起来象无纺的，两个侧面3和5之间的差别在于表面纹理不同。因此，在一个实施方案中，该发明可描述为两个或多个前体纤维网的层压材料，其中所述层压纤维网的两个侧面都基本上被仅来自一个前体纤维网的纤维所覆盖。Since in some embodiments at least one of the layers (e.g., the relatively low elongation polymeric film or tissuesecond precursor web 21 in FIGS. 1 to 4) does not contribute significantly material to the tufts 6 ( For example, in the embodiment shown in FIGS. 1 to 4 ), the web 1 comprising the nonwovenfirst precursor web 20 may be characterized in that on both sides of the web 1 are made of only the nonwoven first precursor.Fiber web 20 contributes fibers as main fibers. Thus, thetufts 6 may be spaced close enough that they effectively cover thefirst side 3 of the web 1 . In such an embodiment, both sides of the web 1 appear to be nonwoven, the difference between the twosides 3 and 5 being the surface texture. Thus, in one embodiment, the invention may be described as a laminate of two or more precursor webs, wherein both sides of the laminated web are substantially covered with covered by fibers.

如图1至4所示，毛簇6的一个特点可为纤维8或纤维18主要的方向对齐。例如，环状、对齐的纤维8可以被描述为具有平行于Z-CD平面的有效矢量分量或主矢量分量，并且当在平面视图(如图4)中观察时该环状纤维8具有相对于横向轴线T基本一致的对齐取向。“环状”纤维8是指纤维8与第一前体纤维网20是一体的且开始和终止于第一前体纤维网20中，但在Z方向上从第二前体纤维网21的第一表面13向外延伸出。关于毛簇6的环状纤维8的“对齐”是指环状纤维8通常全部都被定向从而，如果在如图4的平面图中观察，每一个环状纤维8具有平行于横向轴线T的有效矢量分量，并且优选具有平行于横向轴线T的主矢量分量。As shown in Figures 1 to 4, one characteristic of thetufts 6 may be the alignment of the major directions of the fibers 8 or 18. For example, an annular, aligned fiber 8 can be described as having an effective or principal vector component parallel to the Z-CD plane, and the annular fiber 8 has a relative The transverse axis T is substantially uniformly aligned. "Hoop" fiber 8 means that fiber 8 is integral withfirst precursor web 20 and starts and ends infirst precursor web 20, but moves in the Z direction from thefirst A surface 13 extends outward. "Alignment" with respect to the annular fibers 8 of thetufts 6 means that the annular fibers 8 are generally all oriented such that each annular fiber 8 has an effective vector parallel to the transverse axis T if viewed in plan view as in FIG. component, and preferably has a principal vector component parallel to the transverse axis T.

相反，非环状纤维18与第一前体纤维网20是一体的，但是仅仅开始于第一前体纤维网20中且具有在Z方向上从第二前体纤维网21的第一表面13向外延伸的自由末端。松散纤维18也可具有通常一致的对齐取向，该对齐取向被描述为具有平行于Z-CD平面的有效矢量分量或主矢量分量。In contrast, the non-annular fibers 18 are integral with thefirst precursor web 20, but only originate in thefirst precursor web 20 and have a distance from thefirst surface 13 of thesecond precursor web 21 in the Z direction. Free end extending outward. Loose fibers 18 may also have a generally uniform alignment orientation described as having an effective or principal vector component parallel to the Z-CD plane.

对于环状纤维8和松散纤维18两者而言，由于制造制品时应用的缠绕到辊上或压缩，所述对齐是在任何制造后变形之前毛簇6的特征。For both loop fibers 8 and loose fibers 18, the alignment is characteristic of thetufts 6 prior to any post-manufacturing deformation due to winding onto rolls or compression applied when making the article.

如本文所用，当在如图4所示的平面图中观察时，以偏离纵向轴线L大于45度角定向的环状纤维8具有平行于横向轴线T的有效矢量分量。如本文所用，当在如图4的平面图中观察时，以偏离纵向轴线L大于60度的角定向的环状纤维8具有平行于横向轴线T的主矢量分量。在一个优选的实施方案中，至少50％、更优选至少70％、且更优选至少90％的毛簇6的纤维8具有平行于横向轴线T的一个有效矢量分量，且更优选为平行于横向轴线T的一个主矢量分量。如果需要，纤维的定向可以使用放大部件来确定，例如装有合适测量刻度尺的显微镜。通常，对于在平面视图观察中的非线性纤维片断，将纵向轴线L和环状纤维8均作直线近似可用来确定环状纤维8偏离纵向轴线L的角度。例如，如图4所示，一根纤维8a用粗实线着重显示，而它的直线近似8b以虚线显示。该纤维与纵向轴线成大约80度的角(从L逆时针测量)。As used herein, an annular fiber 8 oriented at an angle greater than 45 degrees from the longitudinal axis L has an effective vector component parallel to the transverse axis T when viewed in plan view as shown in FIG. 4 . As used herein, an annular fiber 8 oriented at an angle greater than 60 degrees from the longitudinal axis L has a principal vector component parallel to the transverse axis T when viewed in plan view as in FIG. 4 . In a preferred embodiment, at least 50%, more preferably at least 70%, and more preferably at least 90% of the fibers 8 of thetufts 6 have an effective vector component parallel to the transverse axis T, and more preferably parallel to the transverse axis T. A principal vector component of axis T. The orientation of the fibers can be determined, if desired, using magnifying means, such as a microscope equipped with a suitable measuring scale. In general, for non-linear fiber segments viewed in plan view, a straight line approximation of both the longitudinal axis L and the loop fiber 8 can be used to determine the angle of the loop fiber 8 from the longitudinal axis L. For example, as shown in Figure 4, one fiber 8a is highlighted with a thick solid line, while itsstraight approximation 8b is shown with a dashed line. The fiber makes an angle of about 80 degrees (measured counterclockwise from L) with respect to the longitudinal axis.

毛簇6中环状纤维8的定向用来对比于纤维组成物并且第一前体纤维网20的定向，对于无纺织网其定向被最好地描述为具有基本无规定向的纤维对齐。在一个机织纤维网实施方案中，毛簇6中环状纤维8的定向可以与上述相同，但第一前体纤维网20的纤维将具有与用来制造纤维网的具体纺织方法(如，四方编织模式)有关的定向。The orientation of the endless fibers 8 in thetufts 6 is used to contrast the fiber composition and the orientation of thefirst precursor web 20, which for a nonwoven web is best described as having a fiber alignment of substantially random orientation. In one woven web embodiment, the orientation of the looped fibers 8 in thetufts 6 can be the same as described above, but the fibers of thefirst precursor web 20 will have the same orientation as the particular weaving process used to make the web (e.g., Square weave pattern) related orientation.

在图1所示的实施方案中，毛簇6的纵向轴线L通常沿MD方向排成一行。因此，毛簇6和纵向轴线L原则上可以沿相对于MD或CD的任何方向排成一行。因此，通常可以说对于每个毛簇6，环状、对齐的纤维8通常正交于纵向轴线L排成一行使得它们具有平行于横向轴线T的有效矢量分量，以及更优选具有平行于横向轴线T的主矢量分量。In the embodiment shown in Figure 1, the longitudinal axes L of thetufts 6 are generally aligned in the MD direction. Thus, thetufts 6 and the longitudinal axis L can in principle be aligned in any direction with respect to MD or CD. Thus, it can generally be said that for eachtuft 6, the annular, aligned fibers 8 are aligned generally orthogonal to the longitudinal axis L such that they have an effective vector component parallel to the transverse axis T, and more preferably have Principal vector components of T.

在一些实施方案中，由于如下所述形成毛簇6的优选方法，主要包括环状、对齐纤维8的毛簇6的另一个特点是其通常的敞形结构，该结构的特征在于限定在毛簇6内部的开口空隙区域10，如图2和3所示。空隙区10可具有的形状为在毛簇6的远端31处较宽或较大，而在毛簇6的基部17处较狭窄。这种形状与用来成形毛簇6的齿的形状相反。“空隙区”不是指完全没有任何纤维的区域；该术语是指作为毛簇6的通常外观的一般描述。因此，可能是在一些毛簇6中一根松散纤维18或多根松散纤维18可以出现在空隙区10中。“开口”空隙区是指毛簇6的两个纵向末端通常敞开且没有纤维，这样使得毛簇6在未压缩状态形成有点象“隧道”的结构，如图3所示。In some embodiments, due to the preferred method of formingtufts 6 as described below, another characteristic oftufts 6 comprising primarily annular, aligned fibers 8 is their generally open configuration, which is characterized by The open void area 10 inside thetuft 6 is shown in FIGS. 2 and 3 . The void area 10 may have a shape that is wider or larger at the distal ends 31 of thetufts 6 and narrower at the base 17 of thetufts 6 . This shape is the opposite of the shape of the teeth used to form thetufts 6 . "Void area" does not mean an area completely free of any fibers; the term is meant as a general description of the usual appearance oftufts 6 . Thus, it may be that in some tufts 6 a loose fiber 18 or a plurality of loose fibers 18 may be present in the interstitial area 10 . "Open" interstitial region means that the two longitudinal ends of thetufts 6 are generally open and free of fibers, so that thetufts 6 form a somewhat "tunnel" structure in the uncompressed state, as shown in FIG. 3 .

另外，由于制造纤维网1的一个优选方法，纤维网1的第二侧面5显示具有间断16，其特征在于通常为线性的缺口(该缺口由第一前体纤维网20的第二表面14的原来无规纤维所限定)已经被成形设备的齿定向地(即，如图1和3所示，在通常正交于MD-CD平面的“Z方向”)推进到毛簇6中，下面将详细描述。第一前体纤维网20原先无规定向的纤维所显示具有的取向的突然改变确定了间断部分16，其显示具有直线性使得它可以被描述为具有通常平行于毛簇6的纵向轴线L的纵向轴线。由于用作第一前体纤维网20的许多无纺织网的性质，间断部分16可能不象毛簇6那样清楚可见。为此，在纤维网1的第二侧面5上的间断部分16观察不到且通常可能检测不到，除非仔细检查纤维网1。同样，纤维网1的第二侧面5可具有非簇状第一前体纤维网20的外观和触感。因而在某些实施方案中，纤维网1在第一侧面3上具有毛巾布的带纹理的外观和感觉，而在第二侧面5上具有相对光滑、柔软的外观和感觉，这两个侧面均由来自同一无纺织网(即，第一前体纤维网20)的纤维所构成。在其它实施方案中，间断部分16可呈现为孔，且可能是经由隧道状毛簇6的末端穿过纤维网1的孔。Additionally, due to a preferred method of making web 1,second side 5 of web 1exhibits discontinuities 16 characterized by generally linear indentations (the indentations defined by the second surface 14 of first precursor web 20). Originally defined by random fibers) have been pushed directionally (i.e., in the "Z direction" generally orthogonal to the MD-CD plane, as shown in Figures 1 and 3) into thetufts 6 by the teeth of the forming device, the following will A detailed description. The abrupt change in orientation exhibited by the originally randomly oriented fibers of thefirst precursor web 20 definesdiscontinuities 16 which exhibit rectilinearity such that it can be described as having a longitudinal axis L generally parallel to thetufts 6. longitudinal axis. Due to the nature of many nonwoven webs used asfirst precursor web 20,discontinuities 16 may not be as clearly visible astufts 6. For this reason, thediscontinuity 16 on thesecond side 5 of the web 1 is not visible and generally may not be detectable unless the web 1 is carefully inspected. Likewise, thesecond side 5 of the web 1 can have the look and feel of the non-tuftedfirst precursor web 20 . Thus in certain embodiments, the web 1 has the textured look and feel of terry cloth on thefirst side 3 and a relatively smooth, soft look and feel on thesecond side 5, both sides Constructed of fibers from the same nonwoven web (ie, first precursor web 20). In other embodiments, thediscontinuities 16 may exhibit holes, and possibly holes through the web 1 via the ends of the tunnel-like tufts 6 .

从对包括无纺第一前体纤维网20的纤维网1的叙述可以看出，毛簇6的纤维8或纤维18可以从第一前体纤维网20的第一表面12或第二表面14起源并延伸。当然毛簇6的纤维8或纤维18也可以从第一前体纤维网20的内部28延伸出来。如图3所示，毛簇6的纤维8或纤维18由于已被推出通常为二维的第一前体纤维网20的平面外(即，如图3所示在“Z方向”被推出)而延伸。通常，毛簇6的纤维8或纤维18包括与第一前体纤维网20的纤维成为一体且从其上延伸的纤维。As can be seen from the description of the web 1 comprising the nonwovenfirst precursor web 20, the fibers 8 or fibers 18 of thetufts 6 can be formed from either the first surface 12 or the second surface 14 of thefirst precursor web 20. originated and extended. Of course, the fibers 8 or fibers 18 of thetufts 6 can also extend from the interior 28 of thefirst precursor web 20 . As shown in FIG. 3, the fibers 8 or fibers 18 of thetufts 6 have been pushed out of the plane of the generally two-dimensional first precursor web 20 (i.e., pushed out in the "Z direction" as shown in FIG. 3 ) And extend. Typically, the fibers 8 or 18 of thetufts 6 comprise fibers integral with and extending from the fibers of thefirst precursor web 20 .

因此，从以上描述中可以理解：在一个实施方案中，纤维网1可被描述成由至少第一和第二前体纤维网的选择性机械变形而形成的层压纤维网，至少所述第一前体纤维网为无纺织网，所述层压纤维网具有第一侧面和第二侧面，所述第一侧面包括第二前体纤维网和多个离散毛簇，每个离散毛簇包括多个为第一前体纤维整体伸出部并延伸穿过第二前体纤维网的簇状纤维；所述第二侧面包括第一前体纤维网。Thus, it will be appreciated from the above description that, in one embodiment, web 1 may be described as a laminated web formed from selective mechanical deformation of at least first and second precursor webs, at least said first A precursor web is a nonwoven web, the laminate web has a first side and a second side, the first side includes a second precursor web and a plurality of discrete tufts, each discrete tuft comprising a plurality of tufted fibers being integral extensions of the first precursor fibers and extending through a second precursor web; the second side comprising the first precursor web.

由于纤维的塑性变形和泊松比效应，纤维8或18的伸长可能伴随着纤维横截面尺寸(例如，对于圆形纤维的直径)的总体减小。因此，毛簇6的对齐环状纤维8可具有的平均纤维直径小于第一前体纤维网20的纤维的平均纤维直径。据信这种纤维直径的减少有助于纤维网1第一侧面3可觉察到的柔软性，取决于第一前体纤维网20的材料性能，该柔软性可与棉毛巾布相媲美。已发现毛簇6在基部17和未端部分31的中间部分纤维横截面尺寸的减小最大。据信这是由于如下更详细公开的优选制造方法造成的。简单来说，如图3所示，据信毛簇6在基部17和未端部分31处的纤维邻近下面更详细描述的辊104的齿110的顶端，并且在加工过程中被摩擦性锁定和固定。因而，毛簇6的中间部分更自由地被拉伸，或延长，并且因此，可经历相应的纤维横截面尺寸的减小。某些第一前体纤维网20的纤维可能横向挤压毛簇6的基部17。毛簇6的基部17甚至可以被关闭(如果来自毛簇6的纤维足够靠近在一起至接触)或保持开口。通常，在基部17处的任何开口都是狭窄的。在基部17处其它纤维的闭合或缩窄或挤压能帮助稳定毛簇6和第二前体纤维网21。Elongation of the fiber 8 or 18 may be accompanied by an overall decrease in fiber cross-sectional dimension (eg, diameter for a round fiber) due to plastic deformation of the fiber and Poisson's ratio effects. Accordingly, the aligned annular fibers 8 of thetufts 6 may have an average fiber diameter that is smaller than the average fiber diameter of the fibers of thefirst precursor web 20 . It is believed that this reduction in fiber diameter contributes to the perceived softness of thefirst side 3 of the web 1 , which is comparable to cotton terry cloth, depending on the material properties of thefirst precursor web 20 . It has been found that the reduction in the cross-sectional dimension of the fibers of thetufts 6 is greatest in the middle portion between the base portion 17 and the end portion 31 . This is believed to be due to the preferred manufacturing method disclosed in more detail below. Briefly, as shown in FIG. 3, it is believed that the fibers of thetufts 6 at the base 17 and end portion 31 are adjacent the tips of the teeth 110 of theroller 104 described in more detail below and are frictionally locked and locked during processing. fixed. Thus, the middle portion of thetufts 6 is more free to be stretched, or elongated, and thus, may experience a corresponding reduction in fiber cross-sectional dimension. Some of the fibers of thefirst precursor web 20 may compress the base 17 of thetufts 6 laterally. The base 17 of thetufts 6 may even be closed (if the fibers from thetufts 6 are close enough together to touch) or remain open. Typically, any openings at the base 17 are narrow. Closure or narrowing or pinching of other fibers at base 17 can help stabilizetufts 6 andsecond precursor web 21 .

参考图5，显示制造本发明纤维网1的一种装置和方法。装置100包括一对互相啮合的辊102和104，每个均绕轴A旋转，轴A在同一平面内是平行的。辊102包括多个凸起106和相应的凹槽108，其绕辊102的整个圆周完整地延伸。辊104类似于辊102，但并非具有绕辊102的整个圆周完整延伸的凸起，辊104包括多排沿圆周延伸的凸起，该凸起已被改进成几排周向间隔的齿110，该齿绕至少一部分辊104以间隔关系延伸。辊104的各排齿110被相应的凹槽112分开。在运转中，辊102和104互相啮合使得辊102的凸起106伸进辊104的凹槽112，而辊104的齿110伸进辊102的凹槽108。这种啮合更详细地显示在下面论述的图6的横截面图中。辊102和104两者或其中之一可通过本领域已知的方法加热，例如使用热油填充辊或电加热辊。Referring to Figure 5, there is shown an apparatus and method for making a web 1 of the present invention. Apparatus 100 includes a pair ofintermeshing rollers 102 and 104, each rotating about an axis A, which are parallel in the same plane. The roller 102 includes a plurality of protrusions 106 and corresponding grooves 108 that extend completely around the entire circumference of the roller 102 .Roller 104 is similar to roller 102, but instead of having protrusions extending completely around the entire circumference of roller 102,roller 104 includes rows of circumferentially extending protrusions which have been modified into rows of circumferentially spaced teeth 110, The teeth extend in spaced relationship around at least a portion of theroller 104 . Each row of teeth 110 ofroller 104 is separated by a corresponding groove 112 . In operation,rollers 102 and 104 intermesh such that protrusions 106 of roller 102 extend into grooves 112 ofroller 104 and teeth 110 ofroller 104 extend into grooves 108 of roller 102 . This engagement is shown in more detail in the cross-sectional view of Figure 6 discussed below. Both or one of therollers 102 and 104 may be heated by methods known in the art, such as using hot oil filled rollers or electrically heated rollers.

在图5中，装置100被显示为具有一个压花辊(如辊104)和一个非压花的带槽辊102的优选构型。然而，在某些实施方案中使用两个压花辊104可能是优选的，这两个压花辊在各自辊的同一相应区域或不同相应区域具有相同的或不同的图案。这种装置可以生产具有从纤维网1的两个侧面突出的毛簇6的纤维网。装置可以被设计成在同一个辊上具有指向相反方向的齿。这将产生在纤维网的两个侧面都制造毛簇6的纤维网。In FIG. 5 , apparatus 100 is shown with a preferred configuration of one embossing roll (eg, roll 104 ) and one non-embossed grooved roll 102 . However, it may be preferred in certain embodiments to use two embossing rolls 104 having the same or different patterns in the same corresponding area or different corresponding areas of the respective rolls. This device makes it possible to produce a web withtufts 6 protruding from both sides of the web 1 . The device can be designed with teeth on the same roller pointing in opposite directions. This will result in a web in whichtufts 6 are produced on both sides of the web.

以商业可行的连续方法制造本发明纤维网1的方法描绘于图5中。纤维网1通过机械变形前体纤维网(如第一和第二前体纤维网20和21)来制造，其每一个在被图5所示的装置加工之前均可以被描述成一般为平面和二维的。“平面的”和“二维的”仅仅是指纤维网以相对于成品纤维网1的平坦状态开始加工，所述成品纤维网由于毛簇6的成形具有明显的、平面外的、Z方向三维性。“平面的”和“二维的”并不指包括任何特殊的平直度、光滑度或维度。A method of making a web 1 of the present invention in a commercially viable continuous process is depicted in FIG. 5 . Web 1 is manufactured by mechanically deforming precursor webs such as first andsecond precursor webs 20 and 21, each of which may be described as generally planar and two-dimensional. "Planar" and "two-dimensional" simply mean that the web starts processing in a flat state relative to the finished web 1, which has a pronounced, out-of-plane, three-dimensionality in the Z direction due to the formation of thetufts 6 sex. "Planar" and "two-dimensional" are not meant to include any particular straightness, smoothness, or dimension.

本发明的方法和装置在许多方面类似于命名为“Web Materials ExhibitingElastic-Like Behavior”的美国专利5,518,801所描述的方法，并在后来的专利文献中被称为“SELF”纤维网，“SELF”代表“结构弹性状薄膜”。然而，本发明的装置和方法与‘801专利中公开的装置和方法之间存在显著的差别，从而在各自制造的纤维网中差别明显。如下所述，辊104的齿110具有与前沿和后沿有关的具体几何性状，其前沿和后沿允许齿基本“穿”过相对的前体纤维网20、21，在本质上使纤维网变形。在一个双层层压纤维网1中，所述齿110将纤维从第一前体纤维网20中推出同时推出平面外并穿过被刺穿的第二前体纤维网21，可以说，由齿110推动纤维8穿过形成毛簇6。因此，本发明的纤维网1可具有松散纤维末端18的毛簇6和/或环状、对齐的纤维8的“隧道状”毛簇6，对齐的纤维8延伸穿过并远离第一侧面3的表面13，不象SELF纤维网的“帐篷状”肋状元件，其每个均具有连续的与之关联的连续侧壁，即，连续的“过渡区域”，且其不具有其中一层穿过另一层的相互贯通。The method and apparatus of the present invention are similar in many respects to that described in U.S. Patent 5,518,801, entitled "Web Materials Exhibiting Elastic-Like Behavior," and later referred to in the patent literature as "SELF" webs, where "SELF" stands for "Structural elastic-like films". However, there are significant differences between the apparatus and method of the present invention and that disclosed in the '801 patent, and thus differences are evident in the webs produced by each. As described below, the teeth 110 of theroll 104 have specific geometries related to leading and trailing edges that allow the teeth to substantially "push through" the opposingprecursor webs 20, 21, essentially deforming the webs . In a two-ply laminated web 1, the teeth 110 push fibers out of thefirst precursor web 20 simultaneously out of plane and through the piercedsecond precursor web 21, so to speak, by The teeth 110 push the fibers 8 through to form thetufts 6 . Thus, the web 1 of the present invention may havetufts 6 of loose fiber ends 18 and/or "tunnel-like"tufts 6 of looped, aligned fibers 8 extending through and away from thefirst side 3 Thesurface 13 of the SELF web, unlike the "tent-like" rib elements of SELF webs, each has a continuous continuous sidewall associated therewith, i.e., a continuous "transition region", and it does not have one layer passing through through another level of interpenetration.

前体纤维网20和21由它们各自的纤维网制造工艺直接提供或者由供给辊间接提供(两者都未示出)，并且在纵向上移至反转啮合的辊102和104的辊隙116。前体纤维网优选保持在足够的纤维网张力使得使用纤维网处理领域已知的方法以通常平整的状态进入辊隙116。当每个前体纤维网20、21通过辊隙116时，与辊102的凹槽108互相啮合的辊104的齿110同时将部分第一前体纤维网20推出第一前体纤维网20的平面外，然后穿过第二前体纤维网21形成毛簇6。实际上，齿110将第一前体纤维网20“推过”或“穿过”第二前体纤维网21。Precursor webs 20 and 21 are provided either directly by their respective web making processes or indirectly by supply rolls (neither shown), and are moved in the machine direction to nip 116 ofcounter-engaging rolls 102 and 104 . The precursor web is preferably maintained at sufficient web tension to enter nip 116 in a generally flat state using methods known in the web handling art. As eachprecursor web 20, 21 passes through the nip 116, the teeth 110 of theroll 104 intermeshing with the grooves 108 of the roll 102 simultaneously push a portion of thefirst precursor web 20 out of thefirst precursor web 20. Out of plane, thetufts 6 are then formed through thesecond precursor web 21 . In effect, the teeth 110 "push" or "through" thefirst precursor web 20 through thesecond precursor web 21 .

当齿110的顶端从第一和第二前体纤维网20、21中挤过时，主要定向于与齿110交叉的CD的部分第一前体纤维网20的纤维被齿110推出第一前体纤维网20的平面外。纤维可由于纤维移动性而被推出平面外，或者它们可由于在Z方向的被拉伸和/或塑性变形而被推出平面外。被齿110推出到平面外的部分第一前体纤维网20挤过第二前体纤维网21，其由于相对较低的延展性而破裂，从而导致形成纤维网1的第一侧面3上的毛簇6。主要定向为通常平行于纵向轴线L，即如图1所示前体纤维网20的MD方向上的第一前体纤维网20的纤维仅仅被齿110伸展开并且基本保持它们原有无规定向的状态。这就是为什么在实施方案(如图1至4中所示的这个)中环状纤维8可显示具有独特纤维定向的原因，该环状纤维8占每个毛簇6纤维的很大百分比，所述毛簇6具有平行于毛簇6的横向轴线T的有效矢量分量或主矢量分量。As the tips of the teeth 110 pass through the first andsecond precursor webs 20, 21, fibers of thefirst precursor web 20 that are primarily oriented in the CD that intersect the teeth 110 are pushed out of the first precursor by the teeth 110. out of the plane of thefiber web 20 . Fibers may be pushed out of plane due to fiber mobility, or they may be pushed out of plane due to being stretched and/or plastically deformed in the Z direction. The portion of thefirst precursor web 20 pushed out of the plane by the teeth 110 squeezes through thesecond precursor web 21, which ruptures due to its relatively low extensibility, resulting in cracks on thefirst side 3 of the formed web 1. Tufts6. The fibers of thefirst precursor web 20 are primarily oriented generally parallel to the longitudinal axis L, i.e. in the MD direction of theprecursor web 20 as shown in FIG. status. This is why in embodiments such as the one shown in Figures 1 to 4, the annular fibers 8 can exhibit a unique fiber orientation, accounting for a large percentage of the fibers of eachtuft 6, so Thetufts 6 have an effective or principal vector component parallel to the transverse axis T of thetufts 6 .

通过上述说明应当理解当纤维网1是用本发明的装置和方法制备时，前体纤维网20、21应当具有与前体纤维网破坏(如由于拉伸应力而破坏)前伸长能力有关的不同材料性质。具体地讲，无纺第一前体纤维网20可具有比第二前体纤维网21更大的纤维移动性和/或更大的纤维伸长特性，使得其纤维可充分移动或拉伸以形成毛簇6，同时第二前体纤维网21破裂，即，不拉伸到形成毛簇所需要的程度。It should be understood from the above description that when the fiber web 1 is prepared by the apparatus and method of the present invention, theprecursor webs 20, 21 should have an different material properties. In particular, nonwovenfirst precursor web 20 can have greater fiber mobility and/or greater fiber elongation characteristics thansecond precursor web 21 such that its fibers can move or stretch sufficiently to Thetufts 6 are formed while thesecond precursor web 21 is ruptured, ie not stretched to the extent required to form the tufts.

无纺前体纤维网的纤维能够伸出平面外而无塑性变形的程度可取决于前体纤维网内部纤维粘合的程度。例如，如果无纺前体纤维网的纤维仅仅是非常松散地互相缠结，那么它们将更容易互相之间滑动(即通过表面蠕动来相对于邻近纤维移动)，并因此更容易伸出平面外以形成毛簇。另一方面，较强粘合(例如通过大量的热点粘合、水缠结法等)的无纺前体纤维网的纤维将更可能需要伸出平面外的毛簇具有更大程度的塑性变形。因此，在一个实施方案中，第一前体纤维网20可以是具有相对较低纤维内部粘合的无纺织网，而第二前体纤维网21可以是具有相对较高纤维内部连接的无纺织网，这样使得第一前体纤维网的纤维可伸出平面，而第二前体纤维网21的纤维不会伸出平面。当将足够的力施用于第一前体纤维网21时，其中的纤维趋于伸展，而第二前体纤维网的纤维不能伸展而趋于破裂。The degree to which the fibers of the nonwoven precursor web can extend out of plane without plastic deformation may depend on the degree of fiber bonding within the precursor web. For example, if the fibers of the nonwoven precursor web are only very loosely entangled with each other, they will more easily slide over each other (i.e., move relative to adjacent fibers by surface creep) and thus stick out of plane more easily. to form tufts. On the other hand, the fibers of a more strongly bonded (e.g., by extensive thermal point bonding, hydroentangling, etc.) nonwoven precursor web will more likely require a greater degree of plastic deformation of the tufts protruding out of plane . Thus, in one embodiment,first precursor web 20 may be a nonwoven web having relatively low interfiber bonding, whilesecond precursor web 21 may be a nonwoven web having relatively high interfiber bonding. The web is such that the fibers of thefirst precursor web 21 protrude out of the plane, while the fibers of thesecond precursor web 21 do not protrude out of the plane. When sufficient force is applied to thefirst precursor web 21, the fibers therein tend to stretch, whereas the fibers of the second precursor web cannot stretch and tend to rupture.

对于给定的最大应变(如，由装置100的齿110施加的应变)，第二前体纤维网21必须在施加的应变所产生的拉伸载荷下实际破坏。也就是说，对于要设置在纤维网1的第一侧面3上的本发明的毛簇6而言，第二前体纤维网21必须具有足够低的纤维移动性(若有的话)和/或相对较低的断裂伸长率使得它局部(即，在应变区)在应变下破裂，从而产生开口4，毛簇6可从该开口中伸出。如果第二前体纤维网21仅在发生应变的区域产生变形或拉伸，但实际上没有破坏从而在其中产生开口4，那么毛簇6可能无法形成。在一个实施方案中，第二前体纤维网21的断裂伸长率在1％至5％的范围内。虽然实际需要的断裂伸长率取决于导致形成纤维网1的应变，但应当理解对大多数实施方案而言，第二前体纤维网21可显示具有的纤维网断裂伸长率为6％、7％、8％、9％、10％或更大。也应当理解实际的断裂伸长率可取决于应变速率，其对于如图5所示的装置而言是线速度的函数。用于本发明的纤维网的断裂伸长率可用本领域已知的方法测量，如使用标准张力测试装置(如Instron，MTS，Thwing-Albert生产的那些)的标准张力测试方法等。For a given maximum strain (eg, the strain applied by the teeth 110 of the device 100), thesecond precursor web 21 must actually fail under the tensile load created by the applied strain. That is, for thetufts 6 of the invention to be arranged on thefirst side 3 of the web 1, thesecond precursor web 21 must have sufficiently low fiber mobility (if any) and/or or relatively low elongation at break such that it locally (ie in the strain zone) ruptures under strain, thereby creating openings 4 from whichtufts 6 can protrude. If thesecond precursor web 21 is only deformed or stretched in the strained regions, but not actually broken to create openings 4 therein, thetufts 6 may not form. In one embodiment, the elongation at break of thesecond precursor web 21 is in the range of 1% to 5%. While the actual desired elongation at break will depend on the strain resulting in web 1, it should be understood that for most embodiments,second precursor web 21 may exhibit a web elongation at break of 6%, 7%, 8%, 9%, 10% or greater. It should also be understood that the actual elongation at break may depend on the strain rate, which for the device shown in FIG. 5 is a function of line speed. The elongation at break of the webs used in the present invention can be measured by methods known in the art, such as standard tensile testing methods using standard tensile testing apparatus (such as those produced by Instron, MTS, Thwing-Albert), and the like.

此外，相对于第一前体纤维网20而言，第二前体纤维网21应当具有较低的纤维移动性(若有的话)和/或较低的断裂伸长率(即，单个纤维的断裂伸长率，或者如果是薄膜，即薄膜的断裂伸长率)使得第二前体纤维网21并非伸出平面外到毛簇6的程度，而是在由形成毛簇6所产生的应变下张力变弱，如通过装置100的齿110。在一个实施方案中，第二前体纤维网21相对第一前体纤维网20而言显示具有足够低的断裂伸长率使得如果完全的话，开口4的翼片7相对毛簇6而言仅稍微伸出平面外。通常，据信第二前体纤维网21应具有的断裂伸长率比第一前体纤维网20小至少10％，优选小至少30％，更优选小至少50％，甚至更优选比第一前体纤维网20的小至少约100％。用于本发明的纤维网的相对断裂伸长率值可用本领域已知的方法测量，如使用标准张力测试装置(如Instron，MTS，Thwing-Albert生产的那些)的标准张力测试方法等。In addition, thesecond precursor web 21 should have lower fiber mobility, if any, and/or lower elongation at break (i.e., individual fibers) relative to thefirst precursor web 20. elongation at break, or in the case of a film, the elongation at break of the film) such that thesecond precursor web 21 does not protrude out of plane to the extent of thetufts 6, but rather within the extent produced by forming thetufts 6 Tension is weakened under strain, such as through the teeth 110 of the device 100 . In one embodiment, thesecond precursor web 21 exhibits a sufficiently low elongation at break relative to thefirst precursor web 20 that the flaps 7 of the openings 4 are only, if at all, relative to thetufts 6. Protrude slightly out of plane. Generally, it is believed that thesecond precursor web 21 should have an elongation at break that is at least 10% less than thefirst precursor web 20, preferably at least 30% less, more preferably at least 50% less, even more preferably than thefirst precursor web 20.Precursor web 20 is at least about 100% smaller. Relative elongation at break values for webs useful in the present invention can be measured by methods known in the art, such as standard tensile testing methods using standard tensile testing apparatus (such as those produced by Instron, MTS, Thwing-Albert), and the like.

在一个实施方案中，第二前体纤维网21可包括基本全部MD定向的纤维，如丝束纤维，使得基本无CD定向的纤维。对于这样一个纤维网1的实施方案，第二前体纤维网21的纤维可容易在毛簇6伸出的开口4处分离。因此，在此实施方案中，第二前体纤维网21不必具有任何最小的断裂伸长率，因为材料的破裂和断裂不是形成开口4的方式。In one embodiment, thesecond precursor web 21 may comprise substantially all MD oriented fibers, such as tow fibers, such that there are substantially no CD oriented fibers. With such a web 1 embodiment, the fibers of thesecond precursor web 21 can be easily separated at the openings 4 through which thetufts 6 protrude. Thus, in this embodiment, thesecond precursor web 21 does not have to have any minimum elongation at break, since cracking and breaking of the material is not the way to form the openings 4 .

毛簇6的数量、间距和大小可通过改变齿110的数量、间距和大小以及必要时对辊104和/或辊102进行相应的尺寸变化来改变。这种改变，连同前体纤维网20、21中可能的变化使得能够制造用于多种用途的许多不同的纤维网1。例如，由包括具有MD和CD机织塑性可延展线的相对高定量纺织物的第一前体纤维网20和包括相对高定量、相对低可延展的合成聚合物无纺材料的第二前体纤维网21制成的纤维网1可制成坚固、多孔的地膜，如用于减少倾斜通道损坏并且使本土植被能够在不稳定的土壤中生长的防腐蚀装置。由包括塑性可延展纺粘聚合物纤维的相对低定量无纺织网的第一前体纤维网20和包括相对低可延展的合成聚合物薄膜的第二前体纤维网21制成的纤维网1可用作毛巾布状织物用于半耐用或耐用衣物，或者用于如WO 01/76523中所述的个人护理用品。如下面更全面地叙述，包括无纺材料/薄膜第一前体纤维网/第二前体纤维网组合的纤维网1也可用作一次性吸收制品中的部件。The number, spacing and size of thetufts 6 can be varied by varying the number, spacing and size of the teeth 110 and, if necessary, corresponding dimensional changes to therollers 104 and/or the rollers 102 . This variation, along with possible variations in theprecursor webs 20, 21, enables the manufacture of many different webs 1 for a variety of uses. For example, from afirst precursor web 20 comprising a relatively high basis weight textile having woven plastically extensible strands in MD and CD and a second precursor comprising a relatively high basis weight, relatively low extensible synthetic polymeric nonwovenmaterial Fiber mesh 21 made of fiber mesh 1 can be made into a strong, porous mulch, such as an anti-corrosion device for reducing damage to inclined channels and enabling native vegetation to grow in unstable soils. Web 1 made from afirst precursor web 20 comprising a relatively low basis weight nonwoven web of plastically extensible spunbond polymer fibers and asecond precursor web 21 comprising a relatively low extensible synthetic polymer film Can be used as a terry-like fabric for semi-durable or durable clothing, or for personal care as described in WO 01/76523. As described more fully below, web 1 comprising a nonwoven/film first precursor web/second precursor web combination may also be used as a component in a disposable absorbent article.

图6表示部分啮合辊102和104与凸起106和齿110的横截面。如图所示，齿110具有齿高TH(注意TH也可应用于凸起高度；在一个优选的实施方案中齿高和凸起高度相等)，和称作段距P的齿-齿间距(或凸起-凸起间距)。如同所示，啮合深度E是辊102和104啮合的量度，并且从凸起106的顶端至齿110的顶端测量。啮合深度E、齿高TH和段距P如果需要可根据前体纤维网20、21的性质和纤维网1的所需特性来改变。例如，通常，啮合程度E越大，第一前体纤维网20的纤维必须具有的必需伸长率或纤维-纤维移动特性越大。同样，毛簇6所需的密度(每单位面积纤维网1上的毛簇6)越大，段距应当越小，并且齿长TL和齿距TD应当越小，如下所述。FIG. 6 shows a cross-section of portions of theintermeshing rollers 102 and 104 with projections 106 and teeth 110 . As shown, the tooth 110 has a tooth height TH (note that TH can also be applied to the protrusion height; in a preferred embodiment the tooth height and the protrusion height are equal), and a tooth-tooth spacing called the pitch P ( or bump-bump spacing). As shown, the depth of engagement E is a measure of the engagement of therollers 102 and 104 and is measured from the tip of the protrusion 106 to the tip of the tooth 110 . The depth of engagement E, tooth height TH and pitch P can be varied, if desired, depending on the properties of theprecursor webs 20, 21 and the desired properties of the web 1 . For example, generally, the greater the degree of engagement E, the greater the requisite elongation or fiber-to-fiber migration properties that the fibers of thefirst precursor web 20 must have. Likewise, the greater the required density of tufts 6 (tufts 6 per unit area of web 1 ), the smaller the pitch should be, and the smaller the tooth length TL and tooth pitch TD should be, as described below.

图7表示具有多个齿110的辊104的一个实施方案，该辊可用于由定量在约60gsm和100gsm之间、优选约80gsm的无纺第一前体纤维网20和密度为约0.91至0.94且定量为约20gsm的聚烯烃薄膜(如，聚乙烯或聚丙烯)第二前体纤维网21制造毛巾布状纤维网1。Figure 7 shows an embodiment of aroll 104 having a plurality of teeth 110 that can be used to form a nonwovenfirst precursor web 20 having a basis weight between about 60 gsm and 100 gsm, preferably about 80 gsm, and a density of about 0.91 to 0.94 And thesecond precursor web 21 of polyolefin film (eg, polyethylene or polypropylene) having a basis weight of about 20 gsm makes the terry cloth-like web 1 .

齿110的放大视图如图8所示。在辊104的这个实施方案中，齿110具有一致的圆周长度尺寸TL，通常从前沿LE至齿顶111处的后沿TE测得为约1.25mm，并且相互间距相同，距离TD为约1.5mm。对于由总定量在约60至约100gsm范围内的纤维网1来制造毛巾布纤维网1，辊104的齿110可具有的长度TL范围从约0.5mm至约3mm，并且间距TD为约0.5mm至约3mm，齿高TH范围为约0.5mm至约5mm，并且段距P在约1mm(0.040英寸)和约5mm(0.200英寸)之间。啮合深度E为约0.5mm至约5mm(直到最大值等于齿高TH)。当然，E、P、TH、TD和TL可相互独立地变化以获得所需的毛簇6的大小、间距和面积密度每单位面积纤维网1的毛簇6数)。An enlarged view of the tooth 110 is shown in FIG. 8 . In this embodiment of theroller 104, the teeth 110 have a uniform circumferential length dimension TL, typically about 1.25 mm measured from the leading edge LE to the trailing edge TE at the tooth crest 111, and are equally spaced from each other at a distance TD of about 1.5 mm . For making a terry web 1 from a web 1 having a total basis weight in the range of about 60 to about 100 gsm, the teeth 110 of theroll 104 may have a length TL ranging from about 0.5 mm to about 3 mm and a pitch TD of about 0.5 mm to about 3 mm, the tooth height TH ranges from about 0.5 mm to about 5 mm, and the pitch P is between about 1 mm (0.040 inches) and about 5 mm (0.200 inches). The depth of engagement E is about 0.5 mm to about 5 mm (up to a maximum value equal to the tooth height TH). Of course, E, P, TH, TD and TL can be varied independently of each other to obtain the desiredtuft 6 size, spacing and areal density (number oftufts 6 per unit area of web 1).

如图8所示，每个齿110具有顶端111、前沿LE和后沿TE。齿顶111是细长的并且通常为纵向定向，与毛簇6和间断部分16的纵向轴线L一致。据信为了得到可被描述成为毛巾布状的纤维网1的起簇的环状毛簇6，LE和TE应该几乎完全正交于辊104的局部周边表面120。最好，从顶端111和LE或TE的过渡应当为锐角，如直角，具有足够小的曲率半径使得齿110于LE和TE处能够挤过第二前体纤维网21。不受理论的约束，据信齿110的顶端和LE与TE之间具有成相对锐角的顶端过渡使得齿110能够“干净地”，也就是说，局部和清楚地穿透前体纤维网20、21，这样使得所得纤维网1的第一侧面3可描述成“簇状”而不是“变形”。当这样加工时，除前体纤维网20和21最初可能具有的弹性外，纤维网1不被赋予任何特别的弹性。穿透前体纤维网21可导致一小部分纤维网21形成“纸屑”或小片。As shown in FIG. 8, each tooth 110 has a tip 111, a leading edge LE and a trailing edge TE. The crests 111 are elongated and generally longitudinally oriented, coinciding with the longitudinal axis L of thetufts 6 anddiscontinuities 16 . It is believed that LE and TE should be almost completely normal to the local peripheral surface 120 of theroll 104 in order to obtain the tuftedendless tufts 6 of what can be described as a terry-cloth-like web 1 . Preferably, the transition from tip 111 and LE or TE should be an acute angle, such as a right angle, with a sufficiently small radius of curvature so that teeth 110 can squeeze throughsecond precursor web 21 at LE and TE. Without being bound by theory, it is believed that the tips of the teeth 110 and the tip transitions between the LE and TE have relatively acute angles that enable the teeth 110 to "cleanly", that is, partially and clearly penetrate theprecursor web 20, 21, so that thefirst side 3 of the resulting fiber web 1 can be described as "tufted" rather than "deformed". When so processed, web 1 is not imparted with any particular elasticity other than thatprecursor webs 20 and 21 may initially have.Penetrating precursor web 21 may result in a small portion ofweb 21 forming "confetti" or flakes.

在较高线速度情况下，即相对较高的纤维网通过旋转辊102和104辊隙的加工速度，类似材料可使毛簇6显示具有非常不同的结构。图9中所示的毛簇6与图2中所示的毛簇的结构类似，只是显示具有非常不同的结构，看起来是典型纺粘无纺材料的结构在相对高速下，即，高应变速率下加工以形成毛簇6。这种结构的典型是毛簇6的最接近部分，即基部17和毛簇6的末端部分，即顶端31之间的断裂纤维和毛簇6顶端看起来是纤维的“簇丛”19的那些。簇丛19包括未断裂的环状纤维8并在毛簇6的顶部被其支撑，并且还包括不再与第一前体纤维网20成为一体的部分断裂纤维11。也就是说簇丛19包括原来与前体纤维网20成为一体但在足够高的线速度下(如在如图5所述的方法中每分钟30米的线速度)加工后完全从前体纤维网20上分离的纤维部分。At higher line speeds, ie, relatively high processing speeds at which the web passes through the nip ofrotating rolls 102 and 104, similar materials can causetufts 6 to exhibit very different structures. Thetufts 6 shown in Figure 9 are similar in structure to the tufts shown in Figure 2, but are shown to have a very different structure, which appears to be that of a typical spunbond nonwoven material at relatively high speed, i.e., high strain Speed down to formtufts 6. Typical of this structure is the closest part of thetuft 6, i.e. the base 17, and the end portion of thetuft 6, i.e. the broken fiber between the tip 31 and those where the top of thetuft 6 appears to be a "tuft" 19 of fibres. . The tufts 19 comprise unbroken annular fibers 8 and are supported by them at the top of thetufts 6 and also comprise partially broken fibers 11 which are no longer integral with thefirst precursor web 20 . That is to say that the tufts 19 include those that were originally integral with theprecursor web 20 but are completely removed from the precursor web after processing at a sufficiently high line speed (such as a line speed of 30 meters per minute in the process as described in FIG. 5 ). 20 separated fiber portions.

因此，从以上描述中可以理解：在一个实施方案中，纤维网1可被描述成由至少第一和第二前体纤维网的选择性机械变形而形成的层压纤维网，至少所述第一前体纤维网为无纺织网，所述层压纤维网具有第一侧面，该第一侧面包括所述第二前体纤维网和多个离散毛簇，每个离散毛簇包括与第一前体纤维网成为一体但伸出第一前体纤维网的纤维和既不与第一前体纤维网为一体又不伸出第一前体纤维网的纤维。Thus, it will be appreciated from the above description that, in one embodiment, web 1 may be described as a laminated web formed from selective mechanical deformation of at least first and second precursor webs, at least said first A precursor web is a nonwoven web, the laminate web having a first side comprising the second precursor web and a plurality of discrete tufts, each discrete tuft comprising a Fibers that are integral to but protrude from the first precursor web and fibers that are neither integral nor protrude from the first precursor web.

尽管据信在毛簇6的未端部分31处观察到的明显纤维定向，如簇丛19，主要是由于加工速度，但也据信它也受其它参数的影响，如第一前体纤维网20的纤维类型和定量以及可影响纤维-纤维粘合的加工温度。纤维的簇丛据信出现在用辊104的齿110的顶端加工时相关的毛簇6部分。据信纤维在齿顶端的摩擦啮合将纤维“锁定”在适当位置，从而限制纤维伸长和/或纤维移动，相信是这两种机理使毛簇6的形成成为可能。因此，可以说一旦锁定在适当的位置，邻近齿110顶端的纤维就可断裂，并且由于前体纤维网的任意缠结以及由于压力和摩擦造成的纤维的可能冷焊，断裂纤维11开始并保持存在于毛簇6末端31的簇丛19中。Although it is believed that the apparent fiber orientation observed at the end portion 31 of thetufts 6, such as tufts 19, is primarily due to processing speed, it is also believed to be influenced by other parameters, such as thefirst precursor web 20 Fiber type and basis weight and processing temperature can affect fiber-fiber bonding. Tufts of fibers are believed to occur at the portion of thetuft 6 associated with processing with the tips of the teeth 110 of theroll 104 . It is believed that the frictional engagement of the fibers at the tooth tips "locks" the fibers in place, thereby limiting fiber elongation and/or fiber movement, both mechanisms believed to enabletuft 6 formation. Thus, it can be said that once locked in place, the fibers adjacent to the tips of the teeth 110 can break, and due to any entanglement of the precursor web and possible cold welding of the fibers due to pressure and friction, the broken fibers 11 initiate and remain Present in tufts 19 at ends 31 oftufts 6 .

具有相对较高定量的第一前体纤维网20通常在簇丛19中具有相对较多的纤维11部分。在一种意义上，看起来好象在生产过程中紧靠近齿顶部110的第一前体纤维网20的大多数纤维成分仅在Z方向被简单置换到毛簇6的未端部分31，产生簇丛19。包括相对低伸长率纤维或具有相对低纤维-纤维移动性(如，相对有限的纤维表面蠕动能力)的纤维的第一前体纤维网20看来可导致相对少量的纤维开始并保持存在于毛簇6末端31处的簇丛19中。纤维-纤维移动性可通过减少或消除纤维-纤维粘合来增加。热粘合在某些无纺织网内可完全消除(即，通过无粘合来避免)、或显著减小以增加纤维-纤维移动性。类似地，水刺纤维网可更少缠结以增加纤维-纤维移动性。对于任何前体纤维网20而言，在如本文所公开的加工之前对它进行润滑也可增加纤维-纤维移动性。例如，可在第一前体纤维网20进入辊102和104的辊隙116前将矿物油润滑剂施用于其上。另外，可将增塑剂如凡士林加入某些合成纤维网如聚乙烯纤维网或聚乙烯与聚丙烯纤维网中，以增强延展性。Afirst precursor web 20 having a relatively higher basis weight typically has a relatively greater portion of fibers 11 in tufts 19 . In one sense, it appears that most of the fiber content of thefirst precursor web 20 close to the tooth tops 110 is simply displaced in the Z direction to the end portions 31 of thetufts 6 during production, resulting in cluster19. Afirst precursor web 20 comprising relatively low elongation fibers or fibers having relatively low fiber-to-fiber mobility (e.g., relatively limited fiber surface creep ability) appears to result in a relatively small number of fibers initially and remaining present in the In the tuft 19 at the end 31 of thetuft 6. Fiber-fiber mobility can be increased by reducing or eliminating fiber-fiber bonding. Thermal bonding can be eliminated entirely (ie, avoided by having no bonds) in certain nonwoven webs, or significantly reduced to increase fiber-fiber mobility. Similarly, hydroentangled webs may be less entangled to increase fiber-to-fiber mobility. As with anyprecursor web 20, lubricating it prior to processing as disclosed herein can also increase fiber-to-fiber mobility. For example, a mineral oil lubricant may be applied tofirst precursor web 20 before it enters nip 116 ofrolls 102 and 104 . In addition, plasticizers such as petrolatum can be added to certain synthetic webs such as polyethylene webs or polyethylene and polypropylene webs to enhance extensibility.

簇丛19存在的结果是纤维网1在其一侧上具有稍微蓬乱、有纹理的效果，可用于例如需要更多擦洗纹理的擦拭物。在一种意义上，在相对低速加工条件下制造时具有软毛巾状触感的纤维网当在完全相同但相对较高线速度条件下加工时，可相对具有研磨的感觉。纤维网上的这种蓬乱、有纹理的触感可用于某些用途，如用于硬质表面清洁擦拭物或脱皮面部擦拭物。因此，不管纤维网1是否需要是柔软或织物状的以和粘性物质一起被施用于身体的红肿部分，如泥敷剂，或用作适形的、半耐用的轻研磨剂以轻轻地从金属弯曲表面上除去灰尘和氧化物，毛簇6形成的速度可以调节以得到需要的纹理。The result of the presence of tufts 19 is that the web 1 has a slightly disheveled, textured effect on one side thereof, useful for example in wipes where more scrubbing texture is desired. In one sense, a web that has a soft towel-like feel when produced at relatively low speed processing conditions can have a relatively abrasive feel when processed at the exact same but relatively high line speed conditions. This disheveled, textured feel to the web can be used in certain applications, such as for hard surface cleaning wipes or peeling facial wipes. Thus, regardless of whether the web 1 needs to be soft or fabric-like to be applied to inflamed parts of the body with viscous substances, such as poultices, or used as a conformable, semi-durable light abrasive to gently remove Dust and oxides are removed from the curved metal surface, and the speed at which thetufts 6 are formed can be adjusted to obtain the desired texture.

不受理论的束缚，据信如果第一前体纤维网的纤维具有高度弯曲的形状，如卷曲纤维，那么与更线性的纤维构象相比，所得毛簇6将具有较多的环状纤维8和较少的断裂纤维18。据信这种纤维构象在两邻近齿之间桥连的机会较少，并且由于它们在其断裂点以上并不容易拉伸，因此形成完整环状结构的机会更大。此外，这些曲线形纤维也可通过使用偏心双组分纤维或并列型双组分纤维(如由聚乙烯和尼龙组成的双组分纤维)来制造。Without being bound by theory, it is believed that if the fibers of the first precursor web have a highly curved shape, such as crimped fibers, the resultingtufts 6 will have more looped fibers 8 as compared to a more linear fiber conformation and fewer broken fibers18. It is believed that this fiber conformation has less chance of bridging between two adjacent teeth and, since they are not easily stretched above their breaking point, a greater chance of forming a complete ring structure. In addition, these curvilinear fibers can also be produced by using eccentric bicomponent fibers or side-by-side bicomponent fibers such as bicomponent fibers composed of polyethylene and nylon.

已发现某些无纺织网，如包括短纤长度纤维的粗梳纤维网，当用作第一前体纤维网20时，在毛簇6中产生非常少的环状纤维8，这样使得在这些纤维网中产生的毛簇6不能被描述成包括多个如以上图1至4所述的环状、对齐的纤维8。而是粗梳无纺织网可产生具有少量(如果有的话)环状、对齐的纤维8和大量(如果不全是的话)未对齐和/或断裂纤维18的毛簇6。据信由粗梳纤维网制成的毛簇6中的纤维的未对齐是部分由于粗梳纤维网纤维成分的性质。人造短纤维不是“无止境的”，而是具有约15mm至约100mm，且更典型约40mm至约80mm的预定长度。因此，当粗梳纤维网用图5所述的装置来加工时，据信存在非常大的这种可能性：松散的纤维末端将位于毛簇6的附近，从而在毛簇6中产生非环状的纤维末端。此外，通常人造短纤维不具有与例如纺粘纤维或熔喷纤维相同的伸长特性。然而，即使毛簇6没有环状纤维，纤维状的毛簇仍然提供柔软的有益效果，并得到具有毛巾布状特性的纤维网。It has been found that certain nonwoven webs, such as carded webs comprising staple length fibers, when used as thefirst precursor web 20, produce very few looped fibers 8 in thetufts 6, such that in theseThe tufts 6 produced in the web cannot be described as comprising a plurality of annular, aligned fibers 8 as described above with respect to Figures 1 to 4 . Instead, carding a nonwoven web can producetufts 6 with a small number, if any, of looped, aligned fibers 8 and a large, if not all, number, if not all, of misaligned and/or broken fibers 18 . It is believed that the misalignment of the fibers intufts 6 made from a carded web is due in part to the nature of the fiber composition of the carded web. Staple fibers are not "endless," but have a predetermined length of from about 15 mm to about 100 mm, and more typically from about 40 mm to about 80 mm. Therefore, when the carded web is processed with the apparatus described in FIG. 5, it is believed that there is a very high probability that loose fiber ends will be located in the vicinity of thetufts 6, thereby creating non-loops in thetufts 6. shaped fiber ends. Furthermore, staple fibers generally do not have the same elongation characteristics as, for example, spunbond or meltblown fibers. However, even though thetufts 6 are free of looped fibers, the fibrous tufts still provide the benefit of softness and result in a web with terry-like properties.

因此，从以上描述中可以理解：在一个实施方案中，纤维网1可被描述成由至少第一和第二前体纤维网的选择性机械变形而形成的层压纤维网，至少所述第一前体纤维网为无纺织网，所述层压纤维网具有第一侧面，该第一侧面包括所述第二前体纤维网和多个离散毛簇，所述毛簇包括与所述第一区域成为一体但伸出所述第一区域的多个纤维。Thus, it will be appreciated from the above description that, in one embodiment, web 1 may be described as a laminated web formed from selective mechanical deformation of at least first and second precursor webs, at least said first A precursor web is a nonwoven web, the laminate web having a first side comprising the second precursor web and a plurality of discrete tufts comprising A region is integral but protrudes from the plurality of fibers of the first region.

如果利用纺织第一前体纤维网20，毛簇6的构造和结构可非常接近于与形成于无纺织网的毛簇6所显示具有的构造和结构相同。例如，如果纺织第一前体纤维网20具有主要定向为横向的可延展经线和/或纬线，当用上述的装置100加工时，齿110趋于分开纵向线(经线或纬线)并且仅将横向线推出平面外。因此，由纺织第一前体纤维网20制成的纤维网1可看起来并感觉非常象毛巾布织物。If a wovenfirst precursor web 20 is utilized, the configuration and structure of thetufts 6 can be very close to the same configuration and structure as shown for thetufts 6 formed from the nonwoven web. For example, if the textilefirst precursor web 20 has extensible warp and/or weft threads oriented primarily in the transverse direction, when processed with apparatus 100 as described above, the teeth 110 tend to separate the longitudinal threads (warp or weft) and The line pushes out of the plane. Thus, the web 1 made from spinning thefirst precursor web 20 can look and feel very much like a terry cloth.

在优选的实施方案中，第一前体纤维网20为无纺织网，其中存在最少量的纤维-纤维粘合。例如，前体纤维网可以是具有离散热点粘合方式的无纺织网，这在无纺织网领域通常为已知的。然而，通常需要使粘合点的数量最少，并且使间距最大以便使毛簇6形成时纤维移动和错位最大。通常，利用具有相对大的直径、和/或相对高的断裂伸长率、和/或相对高的纤维移动性的纤维能产生更好和更清楚成形的毛簇6。In preferred embodiments,first precursor web 20 is a nonwoven web in which there is a minimal amount of fiber-to-fiber bonding. For example, the precursor web can be a nonwoven web having discrete thermal point bonding, as is generally known in the art of nonwoven webs. However, it is generally desirable to minimize the number of bond points and maximize the spacing in order to maximize fiber movement and misalignment as thetufts 6 are formed. In general, better and more clearly formedtufts 6 can be produced using fibers having a relatively large diameter, and/or a relatively high elongation at break, and/or a relatively high fiber mobility.

尽管纤维网1在优选的实施方案中被公开成由两个前体纤维网制成的两层纤维网，但它不必局限于两层。例如，可由三个前体纤维网制成三层或更多的层压材料，只要前体纤维网之一可伸长并从另一层的开口中挤过形成毛簇。例如，纤维网1可包括卫生制品的顶片、次顶片和芯。通常，不必利用粘合剂或其它粘合方法来制造层压纤维网1。Although the web 1 is disclosed in the preferred embodiment as a two-layer web made from two precursor webs, it need not be limited to two layers. For example, three or more laminates can be made from three precursor webs so long as one of the precursor webs can be stretched and squeezed through the openings of the other layer to form tufts. For example, the web 1 may comprise a topsheet, a secondary topsheet and a core of a hygiene article. Typically, it is not necessary to utilize adhesives or other bonding methods to manufacture the laminated web 1 .

纤维网1的组成层(如，前体纤维网20和21以及任何其它层)可依靠毛簇6的“锁定”效应保持在面对面层压关系，所述毛簇6从第二前体纤维网21的开口4中伸出。在某些实施方案中，可能需要使用粘合剂或热结合或其它粘合方法，这取决于纤维网1的最终用途。例如，包括双组分纤维无纺织网的纤维网1可在形成毛簇6后进行对流空气粘合以提供层-层粘合得到更大的抗剥强度。另外，还可能需要将粘合剂施用于前体纤维网之一的至少一部分。例如，在某些实施方案中，层之间的粘合剂、化学粘合、树脂或粉末粘合、或热结合可选择性地施用于前体纤维网的特定区域或全部。例如，在使用粘合剂的情况下，粘合剂可以连续方式施用，如通过槽式涂敷，或以不连续的方式施用，如通过喷雾、挤出等。粘合剂的不连续施用可为条、带、小滴等形式。The constituent layers of web 1 (e.g.,precursor webs 20 and 21 and any other layers) can be held in face-to-face laminated relationship by virtue of the "locking" effect oftufts 6 that are removed from a second precursor web. Stretch out in the opening 4 of 21. In some embodiments, it may be desirable to use adhesives or thermal bonding or other bonding methods, depending on the end use of the web 1 . For example, a web 1 comprising a bicomponent fibrous nonwoven web may be subjected to convective air bonding after formation of thetufts 6 to provide layer-to-layer bonding for greater peel strength. Additionally, it may also be desirable to apply a binder to at least a portion of one of the precursor webs. For example, in certain embodiments, adhesives, chemical bonds, resin or powder bonds, or thermal bonds between layers can be selectively applied to specific regions or all of the precursor web. For example, where an adhesive is used, the adhesive may be applied in a continuous manner, such as by slot coating, or in a discontinuous manner, such as by spraying, extrusion, and the like. Discontinuous applications of adhesive may be in the form of strips, strips, droplets, and the like.

尽管纤维网1在优选的实施方案中公开为包括无纺第一前体纤维网，但实际上，任何前体纤维网都可以是无纺织网、聚合物薄膜、纺织纤维网、或纸幅。当然，不管纤维网特性如何，第一前体纤维网必须具有足够的材料性质如延展性和断裂屈服率以便局部变形成离散的毛簇。同样地，第二前体纤维网必须具有相对小的延展性或断裂屈服率，使得当它用如本文所公开的方法加工时会破裂。Although web 1 is disclosed in a preferred embodiment as comprising a nonwoven first precursor web, virtually any precursor web can be a nonwoven web, a polymeric film, a woven web, or a paper web. Of course, regardless of the web properties, the first precursor web must have sufficient material properties such as ductility and yield to break to locally deform into discrete tufts. Likewise, the second precursor web must have relatively little ductility or yield to fracture so that it will rupture when processed as disclosed herein.

在多层纤维网1中，每个前体纤维网可具有不同的材料性质，从而提供具有有益性质的纤维网1。例如，包括两个(或多个)前体纤维网如第一和第二前体纤维网的纤维网1，可具有有益的流体处理性质以用作一次性吸收制品上的顶片，如下面更全面所描述的。例如，为了优异的流体处理，第一前体纤维网20可由相对亲水的纤维组成。第二前体纤维网21可以是聚合物薄膜如聚乙烯薄膜，并且可以是疏水的或被变为疏水的。当用作一次性吸收制品上的顶片时，这种纤维网的毛簇6可形成上层，即接触身体层。沉积在上层、相对亲水的毛簇上的流体迅速从相对疏水的薄膜上转移至第二薄膜前体纤维网层下的第一前体纤维网部分。观察到的迅速液体转移的一个原因是由变形6的通常对齐纤维8、18所形成的毛细管结构。纤维8、18在相邻纤维之间形成方向对齐的毛细管，并且毛细管作用被总的毛簇6基部17附近的纤维会聚所增强。In a multilayer web 1, each precursor web may have different material properties, thereby providing a web 1 with beneficial properties. For example, a web 1 comprising two (or more) precursor webs, such as a first and a second precursor web, may have beneficial fluid handling properties for use as a topsheet on a disposable absorbent article, as follows described more fully. For example, for superior fluid handling,first precursor web 20 may be composed of relatively hydrophilic fibers.Second precursor web 21 may be a polymeric film, such as a polyethylene film, and may be hydrophobic or rendered hydrophobic. When used as a topsheet on a disposable absorbent article, thetufts 6 of such a web may form the upper layer, ie the body contacting layer. Fluid deposited on the upper, relatively hydrophilic tufts is rapidly transferred from the relatively hydrophobic film to the portion of the first precursor web below the second film precursor web layer. One reason for the observed rapid liquid transfer is the capillary structure formed by the generally aligned fibers 8 , 18 of thedeformation 6 . The fibers 8, 18 form directionally aligned capillaries between adjacent fibers, and the capillary action is enhanced by the convergence of the fibers near the base 17 of theoverall tuft 6.

据信迅速的流体转移由于流体能够通过由环状毛簇6围成的空隙10进入纤维网1而进一步增强。纤维网1的结构所提供的“侧向进入”能力和/或毛细管作用，及/或亲水性梯度使纤维网1成为用于一次性吸收制品的最佳流体处理的理想材料。具体地讲，多层纤维网1可提供流体处理特性方面的甚至更大改进。The rapid fluid transfer is believed to be further enhanced by the ability of fluid to enter the web 1 through the interstices 10 enclosed by theannular tufts 6 . The "side entry" capabilities and/or capillary action provided by the structure of the web 1, and/or the gradient of hydrophilicity make the web 1 an ideal material for optimal fluid handling in disposable absorbent articles. In particular, the multilayer web 1 can provide even greater improvements in fluid handling properties.

取决于所用的前体纤维网20和21以及辊102和包括齿110的尺寸参数，本发明的纤维网1可显示具有宽范围的物理属性。纤维网1可显示具有主观上感觉为柔软至粗糙的纹理范围、从不吸收到非常吸收的吸收性、从相对低堆积体积到相对高堆积体积的膨松度；从低撕裂强度至高撕裂强度的撕裂强度；从无弹性至至少100％弹性可延展的弹性；从相对低耐化学性至高耐化学性的耐化学性，这取决于化学上考虑的和许多其它通常描述为防护性能的可变参量、耐碱性、不透明性、擦拭性能、吸水性、吸油性、透湿性、隔热性、耐气候性、高强度、高撕裂力、抗研磨性、静电控制能力、悬垂性、染料亲合性、安全性等。通常，根据第一前体纤维网20的伸长特性，装置100的尺寸可以改变以制得具有各种各样毛簇6尺寸的纤维网1，所述尺寸包括高度h(如图3所示)，和间距(包括毛簇6的面积密度)。另外，毛簇可容易通过具有辊104上的齿110所显示的所需图案而形成直线状、填充状、和层压纤维网的选择区域等图案。Depending on theprecursor webs 20 and 21 used and the dimensional parameters of the roll 102 and including the teeth 110, the web 1 of the present invention can exhibit a wide range of physical properties. The web 1 may exhibit a texture ranging from subjectively soft to rough, absorbency from no absorbency to very absorbency, bulk from relatively low bulk volume to relatively high bulk volume; low tear strength to high tear strength; Tear strength for strength; stretchable elastic from inelastic to at least 100% elastic; chemical resistance from relatively low to high chemical resistance, depending on chemical considerations and many other commonly described barrier properties Variable parameters, alkali resistance, opacity, wiping performance, water absorption, oil absorption, moisture permeability, heat insulation, weather resistance, high strength, high tear force, abrasion resistance, static control ability, drapability, Dye affinity, safety, etc. Generally, depending on the elongation characteristics of thefirst precursor web 20, the dimensions of the apparatus 100 can be varied to produce a web 1 having a wide variety oftuft 6 sizes, including the height h (as shown in FIG. 3 ). ), and spacing (including the area density of tufts 6). Additionally, the tufts can be easily patterned into lines, fills, and selected areas of the laminated web by having the desired pattern exhibited by the teeth 110 on theroll 104 .

纤维网1可用于各种各样的用途，包括各种过滤片如空气过滤器、袋式过滤器、液体过滤器、真空过滤器、排水过滤器和细菌防护过滤器；用于各种电器的片如电容器隔离纸和软盘包装材料；各种工业片如粘性胶带基布、吸油材料和纸毡；各种擦拭片如家用擦拭物、保养和医学处理、打印辊擦拭物、用于清洁复印机的擦拭物、婴儿擦拭物和用于光学系统的擦拭物；各种医用和卫生片，如外科手术服、手术服、盖布、帽子、面罩、被单、毛巾、纱布、糊剂的基布、尿布、尿布衬里、尿布覆盖层、妇女卫生巾覆盖层、妇女卫生巾或尿布采集层(在覆盖层以下)、尿布芯、卫生棉塞衬里、橡皮膏的基布、湿纸巾和薄纸；各种衣服用的片，如衬布、衬垫、工作服衬里和一次性内衣；各种生活材料片如人造革和合成皮革的基布、桌面、墙纸、干燥剂的填塞、包装材料和包装、购物袋、套装套和枕头套；各种农用片，如地膜和防腐蚀装置、冷却和日光防护服、加衬帘、全部覆盖的片、防光片、农药的包装材料、天然幼树罐的衬里纸；各种保护片如防烟雾面具和防灰尘面具、实验服和防灰尘服；各种土木工程建筑用的片，如房屋围裹层、排水材料、过滤介质、分离材料、覆盖层、屋顶、毛圈和地毯基布、墙内材料、隔音或减振片和固化片；和各种汽车内片，如除了碱性电池的隔离片之外还有小地毯和车内垫毯、模塑顶篷材料、头托、和衬里布。其它用途包括利用纤维网1作为个人清洁或卫生的擦拭物，如用于婴儿擦拭物、面巾或擦拭纸或体巾。The fiber web 1 can be used in a variety of purposes, including various filter sheets such as air filters, bag filters, liquid filters, vacuum filters, drainage filters and bacteria protection filters; Sheets such as capacitor release paper and floppy disk packaging materials; various industrial sheets such as adhesive tape base cloths, oil-absorbing materials, and paper felts; various wiping sheets such as household wipes, maintenance and medical treatments, printing roller wipes, for cleaning copiers Wipes, baby wipes and wipes for optical systems; various medical and sanitary sheets, such as surgical gowns, surgical gowns, drapes, caps, masks, sheets, towels, gauze, base cloth for pastes, diapers , diaper liners, diaper covers, feminine sanitary napkin covers, feminine sanitary napkins or diaper acquisition layers (beneath the cover), diaper cores, tampon liners, bases for adhesive plasters, wet wipes and tissues; miscellaneous Sheets for clothing, such as interlinings, pads, linings for work clothes, and disposable underwear; sheets of various living materials such as base fabrics for artificial leather and synthetic leather, tabletops, wallpaper, desiccant padding, packaging materials and packaging, shopping bags, suits covers and pillowcases; agricultural sheets of all kinds, such as mulch and anti-corrosion devices, cooling and sun protection clothing, lining curtains, full-covering sheets, light-proof sheets, packaging materials for pesticides, lining paper for natural sapling jars; various Various protective sheets such as anti-smoke masks and anti-dust masks, lab coats and dust-proof clothing; sheets for various civil engineering constructions, such as house wrapping, drainage materials, filter media, separation materials, coverings, roofs, terry And carpet base fabrics, wall interior materials, sound insulation or vibration damping sheets and curing sheets; and various automotive interior sheets, such as rugs and interior mats, molded headliner materials in addition to alkaline battery separators , headrest, and lining cloth. Other uses include utilizing the web 1 as a personal cleansing or hygiene wipe, such as for baby wipes, face or wipes or body wipes.

在一个实施方案中，纤维网1或包括纤维网1的复合物可被用作粪便储存元件。纤维网1当被设置在开孔纤维网或薄膜下时可用作次顶片或亚层，以便接受并容纳排便后离开穿着者皮肤的低粘度的粪便或粘稠的身体排泄物。纤维网内或毛簇6之间具有较大总三维体积的本发明实施方案通常提供较强的储存低粘度排泄物的能力。使用这种粪便储存元件或亚层的吸收制品描述于除了别的以外的美国专利5,941,864、5,957,906、6,018,093、6,010,491、6,186,992、和6,414,215中。In one embodiment, the fibrous web 1 or a composite comprising the fibrous web 1 may be used as a faecal storage element. The web 1 can be used as a secondary topsheet or sublayer when positioned under an apertured web or film to receive and contain low viscosity faeces or viscous body exudates that leave the wearer's skin after a bowel movement. Embodiments of the invention having a greater overall three-dimensional volume within the web or between thetufts 6 generally provide a greater ability to store low viscosity excreta. Absorbent articles using such fecal storage elements or sublayers are described in US Patent Nos. 5,941,864, 5,957,906, 6,018,093, 6,010,491, 6,186,992, and 6,414,215, among others.

在一个实施方案中，纤维网1包括无纺第一前体纤维网20和第二前体纤维网，所述无纺第一前体纤维网包含定量为约80gsm的纺粘无纺材料并且包括平均直径为约33微米的聚乙烯/聚丙烯(鞘/芯型)双组分纤维，所述第二前体纤维网包括定量为20gsm的聚乙烯薄膜。在此实施方案中，纤维网1每平方厘米有约24个毛簇6，毛簇6具有多个环状、对齐纤维8，其中每个的平均纤维直径为约18微米。这种类型的纤维网可益于用作一次性吸收制品的顶片，如下面图10所示。例如，这种纤维网1除了在毛簇6区域内以外为流体不可渗透的，所述毛簇6区域可芯吸流体从纤维网1的第一侧面3至第二侧面5。In one embodiment, web 1 includes a nonwovenfirst precursor web 20 comprising a spunbond nonwoven material having a basis weight of about 80 gsm and a second precursor web comprising Polyethylene/polypropylene (sheath/core) bicomponent fibers having an average diameter of about 33 microns, the second precursor web comprising a polyethylene film having a basis weight of 20 gsm. In this embodiment, web 1 has about 24tufts 6 per square centimeter,tufts 6 having a plurality of annular, aligned fibers 8, each having an average fiber diameter of about 18 microns. This type of web can be beneficial for use as a topsheet for a disposable absorbent article, as shown in Figure 10 below. For example, such a web 1 is fluid impermeable except in the region oftufts 6 which can wick fluid from thefirst side 3 to thesecond side 5 of the web 1 .

图10表示部分切除的卫生巾平面图，所述卫生巾将本发明的纤维网1作为它的部件之一。通常，卫生巾200包括底片202、顶片206和设置在顶片206和底片202之间的吸收芯204，所述卫生巾可在周边210附近被接合。卫生巾1可具有侧向伸出部分，通常称作“翼”208，其被设计来包裹卫生巾1使用者的内裤裆区的侧边。卫生巾(包括用作其朝向身体表面的顶片)是本领域熟知的，而且不需要详细说明各种替换和任选设计。除了卫生巾以外，纤维网1还可用于尿布或成人失禁产品或其它一次性卫生制品中。然而，注意纤维网1可用作底片、芯材、顶片、次顶片或翼材料中的一个或多个，或作为它们的部件。纤维网1也可有多层，并包括顶片、次顶片、芯、底片或任何数目的层。Figure 10 shows a partially cutaway plan view of a sanitary napkin having the web 1 of the present invention as one of its components. Generally, the sanitary napkin 200 includes a backsheet 202, a topsheet 206, and an absorbent core 204 disposed between the topsheet 206 and the backsheet 202, which may be joined about a perimeter 210. The sanitary napkin 1 may have laterally extending portions, commonly referred to as "wings" 208, which are designed to wrap around the sides of the crotch region of the panty of the user of the sanitary napkin 1. Sanitary napkins, including topsheets for use as their body-facing surfaces, are well known in the art, and the various alternative and optional designs need not be specified in detail. In addition to sanitary napkins, the fibrous web 1 can also be used in diapers or adult incontinence products or other disposable hygiene articles. Note, however, that the web 1 may be used as or as a component of one or more of the backsheet, core, topsheet, secondary topsheet or wing material. The web 1 can also be multilayered and include a topsheet, subtopsheet, core, backsheet or any number of layers.

纤维网1尤其可用作卫生巾200的顶片206。纤维网1由于其可极好地采集流体并分配至吸收芯204、并极好地防止使用时顶片206的朝向身体表面再次润湿，尤其有益于用作卫生巾的顶片206。再次润湿可能是至少两个原因所致：(1)由于卫生巾200上的压力将吸收的流体挤出；和/或(2)收集在顶片206内或其上的湿度。在优选的顶片206中，两个性质，流体采集和流体保持都达到最大，而再次润湿为最小。换句话讲，优选顶片将显示具有较高的流体采集速率和较低程度的再次润湿。The web 1 is especially useful as the topsheet 206 of the sanitary napkin 200 . The fibrous web 1 is particularly beneficial for use as the topsheet 206 of a sanitary napkin due to its excellent ability to acquire and distribute fluid to the absorbent core 204 and to prevent rewetting of the body facing surface of the topsheet 206 during use. Rewetting may be due to at least two reasons: (1) squeezed out of absorbed fluid due to pressure on the sanitary napkin 200; and/or (2) moisture trapped in or on the topsheet 206. In the preferred topsheet 206, both properties, fluid acquisition and fluid retention, are maximized while rewet is minimized. In other words, preferably the topsheet will exhibit a higher fluid acquisition rate and a lower degree of rewet.

顶片206可使用无纺第一前体纤维网20和流体不可渗透的聚乙烯薄膜第二前体纤维网21制成。组成纤维网的定量可不同，然而，通常出于成本和效益的考虑，约20gsm和80gsm之间的总定量是纤维网1所需要的。当制为薄膜/无纺层压材料时，纤维网1将纤维毛簇的柔软性和流体毛细管作用与流体不可渗透聚合物薄膜的防止再次润湿结合在一起。当使用卫生巾时，包括具有第一侧面3的纤维网1的顶片206作为面向身体侧，而第二侧面5作为与下面吸收芯的流体传输，流体可被纤维网1的第一侧面3上的毛簇6采集然后通过第二前体纤维网21芯吸至纤维网1的第二侧面5，然后其被解吸至吸收芯204中。因为毛簇6是离散的并间隔开，而且被流体不可渗透的第二前体纤维网21隔开，所以可使再次润湿最小。可供选择地，纤维网1可使用第一侧面3作为流体传输侧，而第二侧面5为面向身体侧。这使间断部分16能够可能让流体传输到毛簇6中或通过毛簇6传输。The topsheet 206 can be made using a nonwovenfirst precursor web 20 and a fluid impermeable polyethylene filmsecond precursor web 21 . The basis weights of the constituent webs can vary, however, generally a total basis weight of between about 20 gsm and 80 gsm is desired for the web 1 for cost and efficiency reasons. When made into a film/nonwoven laminate, the web 1 combines the softness and fluid capillary action of fiber tufts with the resistance to rewetting of a fluid impermeable polymer film. When a sanitary napkin is used, the topsheet 206 comprising the fibrous web 1 with thefirst side 3 acts as the body-facing side, while thesecond side 5 acts as a fluid transport with the absorbent core below, and the fluid can be absorbed by thefirst side 3 of the fibrous web 1. Thetufts 6 collected on the top are then wicked through thesecond precursor web 21 to thesecond side 5 of the web 1 where they are then desorbed into the absorbent core 204 . Because thetufts 6 are discrete and spaced apart, and separated by the fluid impermeablesecond precursor web 21, rewetting is minimized. Alternatively, the web 1 may use thefirst side 3 as the fluid transfer side, while thesecond side 5 is the body facing side. This enables thediscontinuity 16 to possibly allow the transfer of fluid into or through thetufts 6 .

图11表示月经卫生棉塞300的部分切除的平面图，所述卫生棉塞将本发明的纤维网1作为它的部件之一。通常，卫生棉塞300包括压缩的吸收芯302和覆盖吸收芯302的流体可渗透的覆盖包裹物304。覆盖包裹物304可延伸出吸收芯302的一端以形成裙边部分306。可提供移除部件如细绳308以便于使用后取出卫生棉塞。卫生棉塞，包括用作其体触表面的覆盖包裹物，是本领域熟知的，并且不需要详细说明各种替换和任选设计。然而，注意纤维网1可用作覆盖包裹物、吸收芯材料或移除部件材料中的一个或多个，或作为它们的部件。Fig. 11 shows a partially cut away plan view of amenstrual tampon 300 which has the fibrous web 1 of the present invention as one of its components. Generally, thetampon 300 includes a compressedabsorbent core 302 and a fluidpermeable cover wrap 304 covering theabsorbent core 302 . Thecover wrap 304 may extend beyond one end of theabsorbent core 302 to form askirt portion 306 . A removal means such as astring 308 may be provided to facilitate removal of the tampon after use. Sanitary tampons, including the covering wraps used for their body-contacting surfaces, are well known in the art, and the various alternative and optional designs need not be specified in detail. Note, however, that the web 1 may be used as or as a component of one or more of a cover wrap, absorbent core material, or removal component material.

以下表1表示如本发明所述的纤维网1的典型实施例，以及与在制备它们的过程中所用装置100有关的尺寸，如上文所公开的。每个所列实施例的简要说明在表1后。Table 1 below represents typical examples of webs 1 according to the present invention, together with their dimensions in relation to the apparatus 100 used in the process of making them, as disclosed above. A brief description of each listed example follows Table 1.

                                           表1：装置尺寸参量和纤维网尺寸的实施例   样品编号   前体纤维网1   前体纤维网2   前体纤维网3   段距(P)<mm>(吋)   啮合(E)<mm>(吋)   齿高(TH)<mm>(吋)  环(h)(mm)  前体纤维网1的平均纤维直径(μm)   环状纤维的平均纤维直径(μm)   1   粗梳PET无纺织网   LDPE薄膜   不适用   <1.5>(0.060)   <3.4>(0.135)   <3.7>(0.145)  1.59  20   18   2   纺粘PE/PP芯/皮无纺织网   铝箔   不适用   <1.5>(0.060)   <3.4>(0.135)   <3.7>(0.145)  1.37  24   13   3   纺粘PE/PP芯/皮无纺织网   30lb牛皮纸   不适用   <1.5>(0.060)   <3.4>(0.135)   <3.7>(0.145)  1.38  24   13   4   纺粘PP无纺织网   气流成网PET无纺织网   纺粘PP无纺织网   <1.5>(0.060)   <3.4>(0.135)   <3.7>(0.145)  1.83  34   28   5   纺粘PP无纺织网   Bounty纸巾   纺粘PP无纺织网   <1.5>(0.060)   <3.4>(0.135)   <3.7>(0.145)  1.8  34Table 1: Examples of device dimensional parameters and web dimensions Sample serial number Precursor web 1Precursor web 2Precursor web 3 Pitch (P)<mm>(inch) Engagement(E)<mm>(inch) Tooth height(TH)<mm>(inch) ring (h) (mm) Average fiber diameter of precursor web 1 (μm) Average fiber diameter of annular fibers (μm) 1 Carded PET Nonwoven Web LDPE film not applicable <1.5>(0.060) <3.4>(0.135) <3.7>(0.145) 1.59 20 18 2 Spunbond PE/PP core/skin nonwoven web aluminum foil not applicable <1.5>(0.060) <3.4>(0.135) <3.7>(0.145) 1.37 twenty four 13 3 Spunbond PE/PP core/skin nonwoven web 30lb kraft paper not applicable <1.5>(0.060) <3.4>(0.135) <3.7>(0.145) 1.38 twenty four 13 4 Spunbond PP Nonwoven Web Airlaid PET Nonwoven Web Spunbond PP Nonwoven Web <1.5>(0.060) <3.4>(0.135) <3.7>(0.145) 1.83 34 28 5 Spunbond PP Nonwoven Web bounty paper towels Spunbond PP Nonwoven Web <1.5>(0.060) <3.4>(0.135) <3.7>(0.145) 1.8 34

图12是样品1的显微照片。样品1的第一前体纤维网为定量为145克每平方米(gsm)的粗梳PET无纺织网，其是由38mm(1.5英寸)短纤长度的聚酯/共聚酯三叶形纤维(型号为F30A，购自FIT(Fiber Innovation Technology)Inc.，JohnsonCity，TN.手工粗梳的。样品1的第二前体纤维网为厚度为0.1mm(0.004英寸)的低密度聚乙烯(LDPE)薄膜，其由Huntsman Film Products Co.，Carrolton OH制造，命名为X420。样品1在如以上图5所述的装置上生产，线速度为大约每分钟3米(每分钟10英尺)。如图12所示，翼片7几乎明显地伸出第二前体纤维网(即，薄膜层)的平面外，并且大约覆盖毛簇6的一半。如上所说明的，当需要更硬、有弹力的毛簇6时这可以是可取的。FIG. 12 is a photomicrograph of Sample 1. FIG. The first precursor web of Sample 1 was a carded PET nonwoven web having a basis weight of 145 grams per square meter (gsm) made of polyester/copolyester trilobal fibers of 38 mm (1.5 inches) staple length (Model F30A, available from FIT (Fiber Innovation Technology) Inc., Johnson City, TN. Carded by hand. The second precursor fiber web of Sample 1 was low-density polyethylene (LDPE) with a thickness of 0.1 mm (0.004 inches). ) film, manufactured by Huntsman Film Products Co., Carrolton OH, named X420. Sample 1 was produced on the device described above in Figure 5, at a line speed of approximately 3 meters per minute (10 feet per minute). As shown 12, the flaps 7 protrude almost significantly out of the plane of the second precursor web (i.e., the film layer) and cover about halfway up thetufts 6. As explained above, when a harder, resilient This may be desirable for tufts of 6.

图13是样品2的显微照片。样品2的第一前体纤维网为定量为30gsm的纺粘PE/PP 50/50芯/皮无纺织网，其由BBA，Simpsonville SC制造。样品2的第二前体纤维网为通过将Fasson^1803铝箔带的粘合剂去除掉(即，擦掉)所获得的铝箔，所述铝箔带购自Avery Dennison，U.S.Specialty Tape Division，PainesvilleOH。样品2在如以上图5所述的装置上生产，线速度为大约每分钟3米(每分钟10英尺)如图13所示，铝箔趋于裂开，而翼片7的塑性变形非常小。FIG. 13 is a photomicrograph ofSample 2. FIG. The first precursor web forSample 2 was a 30 gsm basis weight spunbond PE/PP 50/50 core/sheath nonwoven web manufactured by BBA, Simpsonville SC. The second precursor web ofSample 2 was an aluminum foil obtained by removing the adhesive (ie, rubbing off) Fasson^(R) 1803 aluminum foil tape available from Avery Dennison, US Specialty Tape Division, Painesville OH.Sample 2 was produced on the apparatus described above in Figure 5 at a line speed of approximately 3 meters per minute (10 feet per minute). As shown in Figure 13, the aluminum foil tended to split and the plastic deformation of the flap 7 was very small.

图14是样品3的显微照片。样品3的第一前体纤维网为定量为30gsm的纺粘PE/PP 50/50芯/皮无纺材料，其由BBA，Simpsonville SC制造。样品3的第二前体纤维网为褐色100％可回收的30lb牛皮包装纸，购自任何牛皮纸来源，如UlineShipping Supplies，Waukegan，IL。样品3在如以上图5所述的装置上生产，线速度为大约每分钟3米(每分钟10英尺)如图14所示，牛皮纸的第二前体纤维网可产生类似火山状开口的开口4和翼片7。FIG. 14 is a photomicrograph ofSample 3. FIG. The first precursor web forSample 3 was a 30 gsm basis weight spunbond PE/PP 50/50 core/sheath nonwoven manufactured by BBA, Simpsonville SC. The second precursor web forSample 3 was brown 100% recycled 30 lb kraft wrapping paper, purchased from any kraft paper source such as Uline Shipping Supplies, Waukegan, IL.Sample 3 was produced on the apparatus described above in Figure 5 at a line speed of approximately 3 meters per minute (10 feet per minute). As shown in Figure 14, a second precursor web of kraft paper produced openings resembling volcanic openings 4 and wing 7.

图15是样品4的显微照片，所述样品包括三个前体纤维网。样品4的第一和第三前体纤维网为定量为13.5gsm的纺粘聚丙烯无纺材料，命名为NW30，购自First Quality Nonwovens，Haxleton，PA。第一和第三前体纤维网是外层，将第二前体纤维网夹在中间，所述第二前体纤维网为由44mm(1.75英寸)长的人造短纤维形成的松散粘合气流成网无纺织网，其包括聚酯纤维和PE/PP 50/50芯/皮无纺材料双组分粘合纤维，纤维比率按重量计分别为80/20。聚酯纤维是型号为1311的纤维，而PE/PP纤维是型号为851607的纤维，两种纤维均购自FIT(FiberInnovation Technology)Inc.，Johnson City，TN。样品4在如以上图5所述的装置上生产，线速度为大约每分钟30米(每分钟100英尺)如图15所示，在某些纤维网1的实施方案中可能不谈及翼片7，但只在毛簇6延伸通过的开口附近第二前体纤维网稍微破裂。可看出图15中所示的毛簇6包括两种纤维类型。在中间被夹住的气流纤维网和外层之一的纤维都有助于毛簇6的形成。Figure 15 is a photomicrograph of Sample 4, which includes three precursor webs. The first and third precursor webs of Sample 4 were a 13.5 gsm basis weight spunbond polypropylene nonwoven, designated NW30, available from First Quality Nonwovens, Haxleton, PA. The first and third precursor webs are outer layers sandwiching a second precursor web which is a loosely bonded airflow formed from 44 mm (1.75 inches) long staple fibers Laid nonwoven web comprising polyester fibers and PE/PP 50/50 core/sheath nonwoven bicomponent binder fibers in a fiber ratio of 80/20 by weight, respectively. Polyester fiber is fiber type 1311 and PE/PP fiber is fiber type 851607, both fibers were purchased from FIT (Fiber Innovation Technology) Inc., Johnson City, TN. Sample 4 was produced on the apparatus described above in Figure 5 at a line speed of approximately 30 meters per minute (100 feet per minute). As shown in Figure 15, some web 1 embodiments may not involve flaps 7, but only slightly ruptures the second precursor web near the openings through which thetufts 6 extend. It can be seen that thetuft 6 shown in Figure 15 comprises two fiber types. Both the sandwiched air-laid web and the fibers of one of the outer layers contribute to the formation of thetufts 6 .

从以上本发明的纤维网1和装置100的描述中可以理解，可在不背离本发明的保护范围的情况下制造出许多各种纤维网1的结构，如在附加的权利要求书中受权利要求书保护的那些。例如，纤维网1可用露剂、药剂、清洁流体、抗菌溶液、乳液、芳香剂、表面活性剂涂敷或处理。同样地，装置100可被设置成仅在纤维网1的一部分上形成毛簇6，或形成不同尺寸或面积密度的毛簇6。From the above description of the web 1 and device 100 of the present invention, it will be appreciated that many and various configurations of the web 1 can be made without departing from the scope of the present invention, as defined in the appended claims. those protected by the claims. For example, the web 1 may be coated or treated with lotions, medicaments, cleaning fluids, antibacterial solutions, lotions, fragrances, surfactants. Likewise, the apparatus 100 may be configured to formtufts 6 on only a portion of the web 1, or to formtufts 6 of different sizes or areal densities.

所述生产本发明纤维网的方法的另一个优点是所述纤维网可用其它纤维网生产设备在线生产或用一次性吸收制品生产设备在线生产。另外，还存在可在本发明的加工之前或之后使用的其它固态成形方法。例如，纤维网可如本发明所述加工，然后用拉伸方法开孔，如授予Curro等人的美国专利5,658,639中所述的那个。可供选择地，材料可通过各种方法制成复合材料，如授予Curro等人的美国公布2003/028,165A1中所述的那个方法，或如授予Weber等人的美国专利5,167,897中的环形辊压，然后如本发明所述进行加工。所得纤维网因此可显示具有这些多种材料改性的组合有益效果。Another advantage of the method of producing a web of the present invention is that the web can be produced on-line with other web production equipment or with disposable absorbent article production equipment. In addition, there are other solid state forming methods that can be used before or after the processing of the present invention. For example, a web can be processed as described in the present invention and then apertured by stretching, such as that described in US Patent 5,658,639 to Curro et al. Alternatively, the material can be made into a composite by various methods, such as that described in U.S. Publication 2003/028,165A1 to Curro et al., or endless rolling as in U.S. Patent 5,167,897 to Weber et al. , and then processed as described in the present invention. The resulting webs can thus exhibit the combined benefits of having these multiple material modifications.

在发明详述中引用的所有文献的相关部分均引入本文以供参考；任何文献的引用并不可理解为是对其作为本发明的现有技术的认可。All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art to the present invention.

尽管已说明和描述了本发明的具体实施方案，但对于本领域的技术人员显而易见的是，在不背离本发明的精神和保护范围的情况下可作出许多其它的变化和修改。因此有意识地在附加的权利要求书中包括本发明范围内的所有这些变化和修改。While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims (10)

1. laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, described first side comprises described second precursor web and the tuft that at least one is discrete, and each described discrete tufts has the linear orientation that limits longitudinal axis and comprises a plurality of clustered fibers that divide and extend through described second precursor web as the integral extensions of described first precursor web; Described second side comprises described first precursor web.

2. laminate web as claimed in claim 1, wherein said fiber web comprises a plurality of discrete tufts.

3. laminate web as claimed in claim 1, wherein said first precursor web comprises the non-woven web of basic randomly oriented fiber.

4. laminate web as claimed in claim 1, wherein said fiber comprises non-circular fiber.

5. laminate web as claimed in claim 1, wherein the part of each described tuft with the clearance gap area limiting in described tuft inside.

6. cleaning piece, described cleaning piece comprises the described laminate web of claim 1.

7. laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is the non-woven web that comprises fiber, described laminate web has first side, described first side comprises described second precursor web and a plurality of discrete tufts, and each described discrete tufts comprises with described first precursor web and is one and the fiber that stretches out from described first precursor web and is the fiber that one is not stretched out from described first precursor web again with described first precursor web neither.

8. laminate web as claimed in claim 7, wherein said fiber comprises non-circular fiber.

9. cleaning piece, described cleaning piece comprises the described laminate web of claim 7.

10. disposable absorbent article, described goods have at least one parts that comprise laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, described first side comprises described second precursor web and at least one discrete tufts, each described discrete tufts has the linear orientation that limits longitudinal axis and comprises a plurality of clustered fibers, and described clustered fiber is the integral extensions branch of described first precursor web and extends through described second precursor web; Described second side comprises described first precursor web.

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