CN1091032C - 有基本连续粘合剂网和并置的花样的压花的粘结层压材料 - Google Patents

有基本连续粘合剂网和并置的花样的压花的粘结层压材料 Download PDF

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CN1091032C
CN1091032C CN98810990A CN98810990A CN1091032C CN 1091032 C CN1091032 C CN 1091032C CN 98810990 A CN98810990 A CN 98810990A CN 98810990 A CN98810990 A CN 98810990A CN 1091032 C CN1091032 C CN 1091032C
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凯文·B·麦克尼尔
唐·N·博特曼
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Abstract

本发明涉及有两个层或多个层(12)的层压材料(10)。对各层(12)进行压花，并用粘合剂连接至一起。所述粘合剂(30)形成基本连续的网。基本连续的网增加了粘合剂的强度，增加了层压材料(10)的强度，并且排列在与花样(60)一致的层压材料的X-Y平面内。

Description

有基本连续粘合剂网和并置的花样 的压花的粘结层压材料
                            发明领域
本发明涉及将多层纸在一起压花形成层压材料，更准确地说，本发明涉及利用粘合剂将纸层粘结在一起，以改善强度并连接各花样，以及涉及由此制得的层压材料。
                          发明背景
利用现有技术熟知的方法，已将多层纸以面对面的关系粘结在一起。特别合适的并且在商业上成功的工艺可在具有共同受让人的US5,143,776(1992年9月1日授权于Givens)中发现，在此将其引入作为参考。
通过压花将多层纸结合在一起在本领域也是熟知的。可以通过将突起的配对顶面用粘合剂粘接而完成压花，以便形成突出物与突出物连接这样的层压材料。突出物与突出物连接的压花描述于具有共同受让人的US3,414,459(1968年12月3日授权于Wells)中并在此将其引入作为参考。可用于突出物与突出物连接的压花图案的例子披露于具有共同受让人的US.Des.239,137(1976年3月9日授权于Appleman)中并在此将其引入作为参考。Appleman阐明了在商业上成功的毛巾纸上发现的压花图案。一种变种的突出物与突出物连接的压花图案披露于US 5,443,889(1995年8月22日授权于Ruppel等人)中。
另一种压花是：其中粘合剂连接的花样相互错位的嵌套压花，它们描述于下列文献中：US3,547,723(1970年12月15日授权于Gresham)；US3,556,907(1971年1月19日授权于Nystrand)；US3,708,366(1973年1月2日授权于Donnelly)；US3,738,905(1973年6月12日授权于Thomas)；US3,867,225(1975年2月18日授权于Nystrand)；和US4,483,728(1984年11月20日授权于Bauernfeind)。
另一压花可在具有共同受让人的US5,294,475(1994年3月15日授权于McNeil)中找到，并在此引入作为参考。McNeil披露了其中产生具有床单布状外观和较厚厚度的多层层压材料的双层层压制品。
对于上述三个压花工艺的一个共同特征是：在每一个工艺中，纸张的花样均通过压花辊的突起而挠曲至纸张平面外。然后将粘接各层的粘合剂施加至纸张的花样上。然后利用粘合剂，以面对面的形式将各层粘接至一起。
这些工艺将各层以面对面的关系永久地连接在一起。不幸的是，没有一种工艺能在所得层压材料的平面内产生强度。
压花还用来将美学特征赋予最终的层压材料，这些如披露于下列文献中：GB2225745A(1992年11月18日出版，Chandler)；US5,620,776(1997年4月15日授权于Schulz)；和US4,978,565(1990年12月18日授权于Pigneul等人)。另一赋予层压材料以美学特征的工艺是印刷，如披露于US5,209,953(1993年5月11日授权于Grupe等人)中。不幸的是，这些方法中，没有一种赋予层压材料以美学特征的方法能改善其强度。
US4,522,863(1985年6月11日授权于Keck等人)和US4,915,993(1990年4月10授权于Ten Wolde)披露了改善强度的各种尝试。Keck等人和TenWolde披露了具有中间层的层压材料，所述中间层包含稀布或网眼状增强织物。稀布和增强织物均是添加至层压材料中央的、不同的、独立的、连续层。不幸的是，这种产生强度的方法需要将辅加层夹在两外层之间。该多层仍然必须用粘合剂连接在一起，以形成所希望的整体层压材料。
将基本连续的网状物赋予单层纸上的商业上成功的尝试可在具有共同受让人的US4,637,859(1987年1月20日授权于Trokhan)中找到，在此将其引入作为参考。Trokhan披露了这样一种纸张：它在具有基本连续网的挠曲元件上制得并且对着如扬克式烘缸这样的表面进行压印以形成基本连续的图案。
因此，本发明的目的是提供一种多层层压材料。此外，本发明的目的是提供具有通过压花连接在一起的多层层压材料。本发明的最后一个目的是提供这样的层压材料，所述层压材料带有赋予其强度的、连续网状的粘合剂。
                            发明概述
本发明包括一种层压材料。所述层压材料包含以面对面关系用粘合剂粘结在一起的两层或多层。所述粘合剂以基本连续网的形式夹在各层之间。所述各层通过多个花样进行压花。这些花样垂直于层压材料的平面并且优选朝着其它层变形。这些层在花样处用粘合剂接合在一起。这些花样与粘合剂的基本连续网相一致。
在另一实施方案中，本发明包括以面对面关系用粘合剂粘结在一起的两层或多层层压材料的制造方法。该方法包括提供以面对面关系用粘合剂粘结在一起的至少两层的步骤。各层通过压花连接在一起，借此使第一层的第一面以面对面的关系与第二层的第一面结合，由此，通过许多花样将第一层和第二层连接在一起。许多花样与粘合剂的基本连续的网相一致。
                           附图说明
图1是根据本发明的层压材料的透视图，为清楚起见，层压材料具有部分分离的层。
图2是可以用来实施本发明的装置的简略侧视图。
图3是根据本发明层压材料的一个层内表面的顶视图，该层有两个不同的基本连续的粘合剂网格。
图4A是根据本发明层压材料的一个层内表面的顶视图，该层有叠置在包含独立的封闭图形的粘合剂图案上的粘合剂的连续网格。
图4B是图4A示出的压花图案的一个层内表面的顶视图，该层有包含独立的封闭图形的粘合剂图案，所述封闭图形不沿着花样的轮廓，而是扩大至更加接近于等分粘合剂相邻线之间的间隔。
图4C是具有示于图4A和4B的图案混合的粘合剂图案的层压材料内表面的顶视图。
                         发明详述
参考图1，本发明包括一层压材料10。该层压材料10包含两个层或多个层12。尽管下面的讨论是针对两个层12进行的，但本领域熟练技术人员将明白的是，层压材料10可以包含多于两层的许多层12。
层压材料10的各独立的层12均有第一面20和第二面22。当各层12以面对面关系连接至一起时，每个层12有内表面20和外表面22。第一层12的第一面或内表面20对着另一层12进行取向。每个层12的第二面或外表面22远离另一层12进行取向。
根据本发明的每个层12可以进行常规干燥或穿透干燥。优选的是，包含层12的纸张是穿透干燥或常规干燥的纸张，如下面文献中所述：具有共同受让人的US4,191,609(Trokhan)；US4,514,345(Johnson等人)；US4,528,239(Trokhan)；US4,529,480(Trokhan)；US5,245,025(Trokhan)；US5,275,700(Trokhan)；US5,328,565(Rasch等人)；US5,334,289(Trokhan)；US5,364,504(Smurkoski等人)；US5,527,428(Trokhan等人)；US5,556,509(Trokhan等人)；US5,628,876(Ayers等人)；US5,629,052(Trokhan等人)；以及US5,637,194(Ampulski等人)；在此将其引入作为参考。
可选择的是，根据本发明的纸张可以进行缩短。非强制性的缩短可以通过起皱或湿微收缩来完成。起皱和湿微收缩披露于具有共同受让人的US4,440,597(Wells等人)和US4,191,756(Sawdai)中，在此将其引入作为参考。
如下所述，用粘合剂将各层12连接至一起。合适的粘合剂30是水基粘合剂。优选的是，所述粘合剂30包含聚乙烯醇。可以将聚乙烯醇添加至粘合剂30中，其添加量占重量的百分比为3-7％，优选约5％。
如果希望的话，可以将聚酰胺树脂，更准确地说阳离子聚酰胺树脂添加至粘合剂30中。添加聚酰胺树脂将增加层12的湿强度并增加层压材料10的各层12之间的层间粘结强度。合适的聚酰胺树脂是KYMENE(由HerculesChemical公司出售)。如果将KYMENE选作聚酰胺树脂，那么，其添加量占重量的百分比约1-5％，优选约2-4％，更优选约2.5％。
粘合剂30可以基本连续的图案施加，如图3-4所示。粘合剂可以基本连续图案的形式施加至层压材料10的一个或两个层12上。基本连续的图案描述于上面引入的US4,637,859中。
参考图2，通过本领域已知的方法施加粘合剂30，所述方法包括：喷淋，凸版印刷，以及凹版印刷。如果喷淋粘合剂30的话，如本领域已知的熔喷且螺旋形的粘合剂30图案将是合适的图案，或从雾化喷嘴喷出所希望的图案。
就凹版印刷而言，可以使用图2的装置40。该装置40包括三对轴向平行的粘合剂辊，它们顺序为：凹印辊44，涂布辊48，和压印滚筒50。粘合剂30放在容器42中，并通过凹印辊44从容器42中取出。通过刮刀设备46计量过剩的粘合剂30。所述粘合剂30从凹印辊44输送至涂布辊48上。压印滚筒50与涂布辊48叠置。层12在涂布辊48和压印滚筒50之间通过。优选借助涂布辊48将粘合剂涂布至层12的第一表面即内表面20上。可以基本连续的图案，组合网格或任何其它合适的图案施加粘合剂30。可以提供类似的镜象装置40，对其它层12进行印刷。
借助所述的装置40，粘合剂30可以预定的图案印至每一层12上。优选的是，即使是间接的，也一起调整两个涂布辊48，以致使，一个层12的粘合剂30的希望图案在位置上与另一层12的粘合剂30的希望图案对准。
当然，应该认识到的是，无需用两个涂布辊48将整个基本连续的网印刷在各个层12上。一部分图案，例如图案的纵向部分，可以通过伴随第一层12的涂布辊48进行印刷。另一部分图案，例如图案的横向部分，可以通过第二层12的涂布辊48进行印刷。当将两个层12组合时，将产生整个的网格，它形成了基本连续的网。
在将粘合剂30施加至第一层12，第二层12，或两者之上后，使各层12在用于压花的两个图案辊52之间通过。图案辊52可以是上面引入的US5,294,475中所述的图案辊。另外，图案辊52可以是本领域公知的，用于突出物对突出物或嵌套压花的图案辊。适合于突出物对突出物压花的图案辊52披露于上面引入的US3,414,459中。适合于嵌套压花的图案辊52披露于US3,556,907中。
可以利用本领域熟知的装置(未示出)，一起对涂布辊48和图案辊52进行调整。例如可以使涂布辊48和图案辊52啮合在一起。另外，也可以使两个图案辊52啮合在一起，以保证在两个层12之间进行希望的对准。
另外，对于在线相位调节器而言，可以使用固定驱动器。在线相位调节可通过如本领域已知的连接在系统驱动马达和进行定相的一个辊之间的行星齿轮传动系统来完成。合适的相位调节器由Cone Drive Operations，Inc.(Traverse City，Michigan)制造。
另外，也可以通过改变希望进行相位调整的两个辊之间的层12的通道长度来完成定相。通道长度可通过将空载辊设置在纸幅通道中，并在具有垂直于纸幅通道的矢量分量的方向上对空载辊进行调节而改变。提供相位调整的所有这些装置均是已知的并不构成本发明的一部分。
如图3所示，花样60优选包含有序的重复图案。更优选的是，花样60是相互独立的。相互独立的花样60彼此通过基本连续的非压花区而分开。合适的且商业上成功的花样60的图案包括如图所示的菱形。重要的是，应认识到，尽管许多花样60一起形成菱形图案，但每个独立花样60可以独立于与其它花样60一起形成的图案成形。例如，独立的花样60可以是：如图所示椭圆形的，圆形的，方形的，长方形的等。
层压材料10有相互垂直的纵向和横向。花样60的图案可以有相对于纵向和横向成一定角度排列的主取向。例如图3中示出的图案有成45度角排列的菱形的任一侧的主取向，该取向平分平行于纵向和横向的矢量。
基本连续的粘合剂30的图案，可以排列成这样的主取向图案，该主取向只在相对于纵向和横向的对角线上排列。这种排列使得网在粘合剂30相邻线之间的间距对应花样60相邻行之间的间距。
如果粘合剂30的基本连续网只在纵向和横向排列，并与花样60完全重合，或与至少绝大部分重合的话，粘合剂30的线将有相对紧密的间隔。过于紧靠在一起的粘合剂30的线将是不希望的，这是因为该间隔将增加最终层压材料10的成本，大大降低层压材料10的吸收性，并将使使用者对层压材料10的柔软度感觉产生负面影响。
如果希望的话，可以将具有平行于纵向和横向的主取向的粘合剂30的基本连续的网叠置于具有只在相对于纵向和横向对角线上排列的主取向的粘合剂30的第一基本连续的网上。这种图案使得两种不同的间距可以使用。第一间距相应于花样60相邻重复单元格之间的间隔。第二间距相应于花样60相邻行之间的间隔。
参考图4A，粘合剂30的图案还可以包含独立的闭合的图形。当然，如上所述，独立的闭合的图形可以与花样60的相同的图案对准。这种排列保证了第一层12和第二层12粘结至一起，而无需过量的粘合剂30来连接紧密间隔的花样60。这种排列使用了最少量的粘合剂30，借此减少了柔软度和吸收性的损失。
参考图4B，应理解的是，对于相同图案的花样60，可以使用不同的粘合剂图案。图4B中的粘合剂30的图案相对于花样60形成的闭合的图形扩大了，所述粘合剂30向外延伸至闭合图形之外，而不是同样地且紧密地沿着花样60形成的图案。这种排列提供了这样的优点，即获得了更为接近的等间隔的粘合剂30的线。实际上，应理解的是，对于预定的距离，粘合剂30的线是相互平行的。
参考图4C，对于与图4A和4B中示出的花样60相同的图案，示出了混合的粘合剂30图案。在图4C的粘合剂30图案中，交错的闭合图形具有完全沿着该闭合图形轮廓的粘合剂30图案。另外的闭合图形具有放大至使相邻粘合剂30线之间间隔相等的粘合剂30图案。就柔韧性而言，这种排列预期在具有粘合剂30的围绕线的图形处或之间提供铰接线这样的优点。
应理解的是，在所要求保护的本发明中，有许多其它的组合，变更和变化。例如，无需将花样60局限于椭圆形，而可以是任何希望的形状。此外，花样60的图案无需由许多并置的独立花样60组成，以形成一图案。代之以，所述图案可以通过如本领域熟知的方法，通过连续的花样线60而形成。所述这些组合，变更和变化均被下面的权利要求所覆盖。
正如本领域熟知的那样，根据本发明制得的层压材料10可以是被打孔的和卷取在纸芯上。合适的打孔，切割，以及卷取层压材料10的装置在本领域是熟知的并披露于具有共同受让人的US4,687,153(1987年8月18日授权于McNeil)和US5,660,350(1997年8月26日授权于Byrne等人)中；在此将其引入作为参考。另外，如对于搽面纸，手帕，餐巾纸，擦试布等通常需要进行的那样，可以将根据本发明的层压材料10切割成独立的单元。用于独立薄页纸等包装的例子可在具有共同受让人的US5,664,897(1997年7月8日授权于Young等人)中找到，并在此将其引入作为参考。
应理解的是，对本发明层压材料10的包装和使用并不局限于上面所述的内容。本发明的层压材料10可以许多合适的形式进行包装、运输，以及使用。

Claims (14)

1.一种层压材料，包括有：
以面对面关系用粘合剂连接在一起的两层或多层，
其特征在于，所述粘合剂以基本连续网的形式夹在所述层之间；且
所述层压材料还包括许多花样，所述花样垂直于所述层压材料变形并且用粘合剂连接至所述层上，所述花样与粘合剂的基本连续网相一致。
2.根据权利要求1的层压材料，其特征在于，所述花样包括有序重复的图案。
3.根据权利要求2的层压材料，其特征在于，所述花样是相互独立的。
4.根据权利要求3的层压材料，其特征在于，所述花样的图案包括菱形图案。
5.根据权利要求4的层压材料，其特征在于，所述层压材料有相互垂直的纵向和横向，并且所述花样的图案有相对于所述纵向和所述横向的对角线处进行排列的主取向。
6.根据权利要求5的层压材料，其特征在于，所述粘合剂的所述基本连续的网有大致与所述纵向和所述横向对准的主取向。
7.根据权利要求6的层压材料，其特征在于，还包含粘合剂的基本连续的网，所述粘合剂的所述基本连续的网有相对于所述纵向和所述横向的对角线处排列的主取向。
8.根据权利要求2的层压材料，其特征在于，还包含与所述花样的相同的独立图案对准的粘合剂的独立的闭合图形。
9.根据权利要求1的层压材料，其特征在于包含两层，即第一层和第二层，所述第一层和所述第二层通过以突出物对突出物的花样，用粘合剂连接至一起，所述第一层和所述第二层各自有花样，所述第一层的所述花样与所述第二层的所述花样对准。
10.一种包含以面对面关系连接至一起的两个层的层压材料，每个所述层均有朝所述另一层取向的内表面，和与之相对并远离所述另一层取向的外表面，其特征在于，每个所述层均包含花样和非压花区，所述花样朝向另一所述层的非压花区取向，压在其上并用粘合剂连接至其上，借此，用粘合剂将所述两层连接至一起，所述粘合剂以基本连续网的形式夹在所述两层之间。
11.根据权利要求10的层压材料，其特征在于，所述花样包括有序重复的图案。
12.根据权利要求11的层压材料，其特征在于，所述花样是相互独立的。
13.根据权利要求12的层压材料，其特征在于，所述花样的图案包括菱形图案。
14.根据权利要求13的层压材料，其特征在于，所述层压材料有相互垂直的纵向和横向，并且所述花样的图案有相对于所述纵向和所述横向的对角线处进行排列的主取向。
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JP2003505285A (ja) 2003-02-12
KR20010024112A (ko) 2001-03-26
ID26015A (id) 2000-11-16
ZA988509B (en) 1999-03-18
CO4810387A1 (es) 1999-06-30
CA2303387A1 (en) 1999-03-25
WO1999014034A1 (en) 1999-03-25
NO20001367D0 (no) 2000-03-16
TW436424B (en) 2001-05-28
NO20001367L (no) 2000-05-16
CN1278760A (zh) 2001-01-03
IL135035A (en) 2003-03-12
HK1036250A1 (en) 2001-12-28
IL135035A0 (en) 2001-05-20
AU8881798A (en) 1999-04-05
CA2303387C (en) 2004-01-20
US6129972A (en) 2000-10-10

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