Composite fiber layer, manufacturing device, manufacturing method and absorbent product thereof

Abstract

The present application relates to a manufacturing device for a composite fiber layer, comprising a main roller, a first auxiliary roller matched with the main roller, a first fiber layer feeding mechanism, a second auxiliary roller matched with the main roller, a bonding mechanism, and a second fiber layer feeding mechanism. An embossing member and a hole-opening member are provided on the roller surface of the main roller. A first hole-opening pair is provided on the roller surface of the first auxiliary roller. The first hole-opening pair is used to cooperate with the hole-opening member to form a first hole on the first fiber layer. The first fiber layer feeding mechanism is used to feed the first fiber layer between the main roller and the first auxiliary roller. The second auxiliary roller is arranged downstream of the first auxiliary roller. An embossing pair is provided on the roller surface of the second auxiliary roller. The embossing pair is used to cooperate with the embossing member to form an embossed surface on the first fiber layer. The bonding mechanism is used to bond the first fiber layer to the second fiber layer. The second fiber layer feeding mechanism is used to feed the second fiber layer between the main roller and the bonding mechanism. The present application also relates to a composite fiber layer, a manufacturing method thereof, and an absorbent product.

Description

Technical Field

[0001] The present invention relates to the technical field of fiber layers, and in particular to a composite fiber layer and a manufacturing device, a manufacturing method and an absorbent product thereof. Background Art

[0002] With the development of personal hygiene products, people have higher and higher requirements on the breathability and wearing comfort of personal hygiene products. At present, such fiber products can be divided into single-layer fiber layer products and double-layer fiber layer products according to the number of fiber layers.

[0003] For single-layer fiber products, in the traditional manufacturing process, perforation and embossing are performed simultaneously. However, the embossed single-layer fiber layer has poor three-dimensional retention, which in turn affects the breathability and dryness of the finished product, and also damages the appearance of the product, resulting in a decrease in user experience.

[0004] To this end, a double-layer fiber ply product is provided in the conventional art to overcome the above-mentioned defects of the single-layer fiber ply product.

[0005] Chinese patent document CN107531009B provides a method for forming a double-layer laminate, wherein the method uses a traditional two-roller cooperation method to simultaneously perform a punching and embossing process on a first fiber layer, and directly bonds the first fiber layer to a second fiber layer in a subsequent process to form a double-layer composite fiber layer. Summary of the invention

[0006] Various exemplary embodiments of the present application provide a composite fiber layer, a manufacturing device, a manufacturing method, and an absorbent article thereof.

[0007] One aspect of the present application provides a manufacturing device for a composite fiber layer, comprising: a main roller, a roller surface of which is provided with a plurality of embossed parts and a plurality of opening parts; a first auxiliary roller, arranged to cooperate with the main roller, a roller surface of which is provided with a plurality of first opening pairs, the plurality of first opening pairs are used to cooperate with the plurality of opening parts to form a plurality of first openings on the first fiber layer; a first fiber layer feeding mechanism, used to feed the first fiber layer between the main roller and the first auxiliary roller; a second auxiliary roller, arranged to cooperate with the main roller and arranged downstream of the first auxiliary roller, a roller surface of which is provided with a plurality of embossed pairs, the plurality of embossed pairs are used to cooperate with the plurality of embossed parts to form a plurality of embossed surfaces on the first fiber layer; a bonding mechanism, used to bond the first fiber layer to the second fiber layer; and a second fiber layer feeding mechanism, used to feed the second fiber layer between the main roller and the bonding mechanism.

[0008] In one embodiment, the fitting clearance between the main roller and the first auxiliary roller is smaller than the fitting clearance between the main roller and the second auxiliary roller.

[0009] In one embodiment, the device further comprises a temperature regulating device, wherein the temperature regulating device is used to regulate the temperature of the roller surface of each roller so that the roller surface temperature of the first auxiliary roller is greater than or equal to the roller surface temperature of the second auxiliary roller.

[0010] In one embodiment, each of the plurality of opening members includes at least one opening needle fixed on the roller surface of the main roller. Each of the plurality of first opening pairs includes an opening boss fixed on the roller surface of the first auxiliary roller. The surface of the opening boss facing away from the first auxiliary roller is provided with at least one opening matched with the at least one opening needle, and the height of the at least one opening needle is less than or equal to the depth of the at least one matching opening.

[0011] In one embodiment, the embossing member includes a plurality of embossing pins, and the embossing counter member includes a plurality of corresponding embossing grooves. The outer diameter of the embossing pin is smaller than the inner diameter of the embossing groove so that the embossing pin can extend into the embossing groove, and the height of the embossing pin is less than or equal to the depth of the embossing groove.

[0012] In one embodiment, a surface of the embossing pin facing away from the main roller is provided with a central recess, and a projection of the central recess on the surface is located within the surface.

[0013] In one embodiment, the bonding mechanism includes at least one of a thermal bonding device, an adhesive bonding device, or an ultrasonic bonding device.

[0014] In one embodiment, the device further includes: a third auxiliary roller, which is configured to cooperate with the main roller and is disposed between the first auxiliary roller and the second auxiliary roller, and a plurality of second opening pairs are provided on the roller surface of the third auxiliary roller, and the plurality of second opening pairs are used to cooperate with the plurality of opening members to form a plurality of second openings on the third fiber layer; and a third fiber layer feeding mechanism, which is used to feed the third fiber layer between the main roller and the third auxiliary roller. The bonding mechanism is used to bond the first fiber layer and the third fiber layer with the second fiber layer, and the second fiber layer feeding mechanism is used to feed the second fiber layer between the main roller and the bonding mechanism to bond with the first fiber layer and the third fiber layer.

[0015] Another aspect of the present application also provides a method for manufacturing a composite fiber layer, comprising:

[0016] Providing a manufacturing device for the composite fiber layer according to any one of the above embodiments;

[0017] The first fiber layer feeding mechanism feeds the first fiber layer between the main roller and the first auxiliary roller, and the main roller and the first auxiliary roller rotate in opposite directions to each other and cooperate with each other to form the plurality of first openings on the first fiber layer;

[0018] The main roller uses the plurality of openings to position and convey the first fiber layer, and conveys the first fiber layer between the main roller and the second auxiliary roller, wherein the main roller and the second auxiliary roller rotate in opposite directions to each other and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer;

[0019] The main roller uses the plurality of openings to position and convey the first fiber layer, and conveys the first fiber layer between the main roller and the bonding mechanism, the second fiber layer conveying mechanism conveys the second fiber layer between the main roller and the bonding mechanism, and the bonding structure bonds the first fiber layer and the second fiber layer to form a composite fiber layer;

[0020] The main roller positions and conveys the composite fiber layer by using the plurality of openings, and delivers the composite fiber layer to roll up the forming cloth.

[0021] Another aspect of the present application also provides a method for manufacturing a composite fiber layer, comprising:

[0022] Providing a manufacturing device for the above-mentioned composite fiber layer;

[0023] The third fiber layer feeding mechanism feeds the third fiber layer between the main roller and the third auxiliary roller, and the main roller and the third auxiliary roller rotate in opposite directions and cooperate with each other to form the plurality of second openings on the third fiber layer;

[0024] The main roller uses the plurality of openings to position and convey the third fiber layer, and feeds the third fiber layer between the main roller and the first auxiliary roller, and the first fiber layer feeding mechanism also feeds the first fiber layer between the main roller and the first auxiliary roller, and the main roller and the first auxiliary roller rotate in opposite directions and cooperate with each other to form the plurality of first openings on the first fiber layer;

[0025] The main roller positions and conveys the first fiber layer and the third fiber layer by using the plurality of opening members, and conveys the first fiber layer and the third fiber layer between the main roller and the second auxiliary roller, and the main roller and the second auxiliary roller rotate in opposite directions and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer and the third fiber layer;

[0026] The main roller uses the plurality of openings to position and convey the first fiber layer and the third fiber layer, and feeds the first fiber layer and the third fiber layer between the main roller and the bonding mechanism, the second fiber layer feeding mechanism feeds the second fiber layer between the main roller and the bonding mechanism, and the bonding structure bonds the first fiber layer and the third fiber layer to the second fiber layer to form a composite fiber layer;

[0027] The main roller positions and conveys the composite fiber layer by using the plurality of openings, and delivers the composite fiber layer to roll up the forming cloth.

[0028] Another aspect of the present application provides a composite fiber layer formed by the device provided by the above embodiment.

[0029] Yet another aspect of the present application provides an absorbent product made of at least the above composite fiber layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0031] Figure 1 This is a schematic structural diagram of a device for manufacturing a composite fiber layer according to an embodiment of the present application;

[0032] Figure 2 This is a schematic structural diagram of a device for manufacturing a composite fiber layer according to another embodiment of the present application;

[0033] Figure 3A for Figure 1 and Figure 2 A schematic diagram of the cooperation between the main roller and the first auxiliary roller at A in the embodiment shown;

[0034] Figure 3B for Figure 1 and Figure 2 A schematic diagram of the cooperation between the main roller and the second auxiliary roller at B in the embodiment shown;

[0035] Figure 3C for Figure 2 A schematic diagram of the cooperation between the main roller and the third auxiliary roller at position C in the embodiment shown;

[0036] Figure 4A is a schematic diagram of a pattern of a composite fiber layer formed by a device according to an embodiment of the present application;

[0037] Figure 4Bis a schematic diagram of a pattern of a composite fiber layer formed by a device according to another embodiment of the present application;

[0038] Figure 4C is a schematic diagram of a pattern of a composite fiber layer formed by a device according to another embodiment of the present application;

[0039] Figure 4D is a schematic diagram of a pattern of a composite fiber layer formed by a device according to another embodiment of the present application;

[0040] Figure 5A for Figure 1 A schematic top view of a double-layer composite fiber layer formed by the manufacturing device shown;

[0041] Figure 5B for Figure 5A The schematic cross-sectional view of the double-layer composite fiber layer at the FF line is shown;

[0042] Figure 5C for Figure 5B The cross-sectional schematic diagram shown is a partial enlarged view at position I;

[0043] Fig. 6A for Figure 2 A schematic top view of a three-layer composite fiber layer formed by the manufacturing device shown;

[0044] Figure 6B for Fig. 6A The schematic cross-sectional view of the three-layer composite fiber layer at the HH line is shown;

[0045] Figure 6C for Figure 6B The cross-sectional schematic diagram shown is a partial enlarged view at position II;

[0046] Figure 7 This is a flow chart of a method for manufacturing a composite fiber layer according to an embodiment of the present application;

[0047] Figure 8 This is a flow chart of a method for manufacturing a composite fiber layer according to another embodiment of the present application. DETAILED DESCRIPTION

[0048] The terms "primary", "secondary", "first", and "secondary" used in this application are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, features defined as "first" and "secondary" may explicitly or implicitly include one or more of the features.

[0049] Unless explicitly defined otherwise, in the present application, when an element is referred to as being “fixed to” another element, it may be directly connected to the other element or there may be an intervening element.

[0050] Unless otherwise defined, the terms "upstream" and "downstream" used in the present application are only used to describe the relative positioning of an element in the conveying direction of the fiber layer, and are not intended to limit the front end or rear end of the element.

[0051] As mentioned above, in the conventional technology for manufacturing a composite fiber layer, a conventional two-roller cooperation method is used to simultaneously perform a hole-opening and embossing process on the first fiber layer, and the first fiber layer is directly bonded to the second fiber layer in a subsequent process to form a double-layer composite fiber layer. However, the inventors have found in practice that when using this method to manufacture a composite fiber layer, there are the following defects:

[0052] 1) When the gap between the two rollers needs to be further reduced due to the small opening, the embossing matching mechanism and the opening matching mechanism will interfere with each other, making the embossed surface of the fiber layer hard, resulting in the formation of volcanic crater-like pits in the final molded product after winding, which greatly reduces the feel and comfort. In severe cases, the opening needle or embossing pin may break.

[0053] 2) When the fitting clearance is increased to avoid mutual interference between the hole fitting mechanism and the embossing fitting mechanism, although this can improve the softness of the embossed surface, it will also cause the embossing pin and the fiber layer to not fit tightly, causing the fiber layer to fall off the outer surface of the embossing pin during transportation, resulting in inaccurate bonding position in the subsequent bonding process, wrinkles in the composite fiber layer after bonding, damage to the embossed pattern, or uneven embossed patterns, resulting in tilted or flattened embossed patterns on the molded product after winding.

[0054] 3) Since temperature adjustment will affect both the hole opening quality and the embossing quality, that is, the hole opening quality and the embossing quality will interfere with each other in temperature adjustment, when it is necessary to increase the temperature on the roller to improve the hole opening quality, the embossed surface will also become hard due to the increase in roller temperature. When the temperature is adjusted too low, the hole opening quality will be affected.

[0055] Due to the above defects of traditional technology, during the manufacturing process, the roller speed cannot be fast (generally cannot exceed 40 meters / minute), the finished product output is low (the roller width is up to 800mm), the equipment life is not long (generally only about 8 months) and the final product yield is not high (the highest is about 80%).

[0056] Based on this, the inventor found that a better technical solution is urgently needed.

[0057] In order to make the purpose, technical solution and advantages of the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0058] Please combine Figure 3A-3B Reference Figure 1 , Figure 1 This is a schematic structural diagram of a device for manufacturing a composite fiber layer according to an embodiment of the present application. Figure 3A for Figure 1 The schematic diagram of the cooperation between the main roller and the first auxiliary roller at A in the embodiment shown in the figure is as follows: Figure 3B for Figure 1 Schematic diagram of the cooperation between the main roller and the second auxiliary roller at B in the illustrated embodiment. Figure 1 The manufacturing device shown includes a main roller 3, a first auxiliary roller 2, a first fiber layer feeding mechanism 7, a second auxiliary roller 4, an ultrasonic bonding mechanism 5, a thermal bonding mechanism 9 and a second fiber layer feeding mechanism 6.

[0059] Please combine Figure 3A Reference Figure 1 , a plurality of embossed parts 340 and a plurality of opening parts 320 are fixedly provided on the roller surface S1 of the main roller 3. The embossed parts 340 and the opening parts 320 are arranged so as not to interfere with each other, that is, the area where the embossed parts 340 are arranged and the area where the opening parts 320 are arranged do not overlap. Both the embossed parts 340 and the opening parts 320 are fixed on the roller surface S1 of the main roller 3 and extend radially outward. Both the embossed parts 340 and the opening parts 320 can be distributed alternately on the roller surface S1 according to a specific rule, for example, they can be distributed on the roller surface S1 in an array. The surface 344 of the embossed part 340 away from the main roller 3 forms the outer surface S2 of the main roller outside the roller surface S1 of the main roller 3, that is, the cylinder formed by the outer surface S2 of the main roller is coaxial and parallel to the cylinder formed by the roller surface S1 of the main roller 3 and its radius is greater than the radius of the cylinder formed by the roller surface S1 of the main roller 3. Therefore, the embossing part 340 is used to cooperate with the second auxiliary roller 4 to emboss the fiber layer, and the embossed surface of the fiber layer is pressed against the surface 344 of the embossing part 340 away from the main roller 3, that is, the embossed surface is pressed against the outer surface S2 of the main roller, so as to facilitate the bonding of the bonding device and the main roller during the bonding process.

[0060] In one embodiment, each embossing member 340 may be composed of one or more embossing pins 346. When there are multiple embossing pins 346, these embossing pins 346 may be arranged in a specific rule or a specific pattern. For example, the number of multiple embossing pins 346 of each embossing member 340 may be 1, 3, 4, or 8, and the present application does not specifically limit the number. Multiple embossing pins 346 may be arranged in a "cross shape", "star shape", "triangle shape", "curve shape", etc., and the present application does not specifically limit this.

[0061] The hole-opening member 320 is used to cooperate with the first auxiliary roller 2 to open holes on the fiber layer. In one embodiment, each hole-opening member 320 can be composed of one or more hole-opening needles 322. When there are multiple hole-opening needles 322, these hole-opening needles 322 can be arranged in a specific rule or a specific pattern. For example, the number of multiple hole-opening needles 322 can be 1, 5, 7, or 13, and the present application does not specifically limit the number of hole-opening needles 322. Multiple hole-opening needles 322 can be arranged in a "snowflake type", "winter plum type", etc., and the present application does not specifically limit this. In addition, the heights of multiple hole-opening needles 322 in a hole-opening member 320 can be the same or different. When the heights of multiple hole-opening needles 322 are different, for example, the height of the hole-opening needles 322 in the middle area is higher, while the height of the hole-opening needles 322 in the edge area is lower, so that when the hole is opened in the manufacturing process, the opening in the central area of ​​the formed bulge is larger, while the opening at the edge is smaller, fitting the arc of the bulge.

[0062] The height of the embossing member 340 needs to be greater than or equal to the height of the plurality of opening members 320, so that the main roller outer surface S2 formed by the surface 344 of the embossing member 340 that is away from the main roller 3 is radially located outside the surface S3 formed by the apex of the opening member 320, avoiding the need to set a patterned heating plate or a patterned heating member corresponding to the arrangement pattern of the embossing member 340 on the bonding device, thereby simplifying the complexity of the device and saving the cost of the device. However, it is understandable that the height of the embossing member 340 can also be less than the height of the opening member 320, so that the main roller outer surface S2 formed by the surface 344 of the embossing member 340 that is away from the main roller 3 is radially located within the surface S3 formed by the apex of the opening member 320. At this time, a patterned heating plate or a patterned heating member corresponding to the arrangement pattern of the embossing member 340 needs to be set on the bonding device to avoid pressing the opening member. Those skilled in the art should be aware of various embodiments of setting such a patterned heating plate or heating member on the bonding device, which will not be repeated here.

[0063] The first auxiliary roller 2 is configured to cooperate with the main roller 3. A plurality of first opening pairs 220 are fixedly provided on the roller surface of the first auxiliary roller 2. The plurality of first opening pairs 220 are used to cooperate with the plurality of openings 320 on the main roller 3 to form a plurality of first openings on the first fiber layer. It is understood that the arrangement of the plurality of first opening pairs 220 on the first auxiliary roller 2 corresponds to the arrangement of the plurality of openings 320. The matching gap between the first auxiliary roller 2 and the main roller 3 can be adjusted according to the material, thickness and / or the influence of the temperature on the two rollers on the first fiber layer. It should be understood that the matching gap between the two rollers refers to the gap left for the fiber layer between the two rollers when the two rollers are rolling. In one embodiment, for the matching of the first auxiliary roller 2 and the main roller 3, the matching gap refers to the distance between the roller surface S1 of the main roller 3 and the surface S4 of the first opening pair 220 closest to the roller surface S1 facing the main roller 3 when rolling the first fiber layer. Usually, the matching gap between the first auxiliary roller 2 and the main roller 3 is slightly larger than the thickness of the first fiber layer.

[0064] In this embodiment, the first opening pair 220 includes an opening boss 222 fixed on the roller surface of the first auxiliary roller 2. The surface of the opening boss 222 facing away from the first auxiliary roller 2 is provided with an opening 224 arranged correspondingly to the opening needle 322. The height of the opening needle 322 can be less than or equal to the depth of the corresponding opening 224, so that the opening needle 322 can completely enter the corresponding opening 224 during rolling and will not touch or just touch the bottom surface of the corresponding opening 224. In addition, when the height of the opening needle 322 is less than the depth of the corresponding opening 224, the opening needle 322 is conical, and the diameter of the thickest part of the opening needle 322 is less than the diameter of the corresponding opening 224, the size of the opening can be controlled by the degree to which the opening needle 322 enters the opening 224. Such a setting can also ensure that the opening needle 322 is not easy to break when adjusting the matching clearance.

[0065] The first fiber layer feeding mechanism 7 is used to feed the first fiber layer between the main roller 3 and the first auxiliary roller 2. In this embodiment, the first fiber layer feeding mechanism 7 is provided with a driving device. The driving device drives the first fiber layer feeding mechanism 7 to tension the first fiber layer and transport it to between the main roller 3 and the first auxiliary roller 2 through a cloth guide wheel 1.

[0066] Please combine Figure 3B Reference Figure 1, the second auxiliary roller 4 is arranged to cooperate with the main roller 2 and is arranged downstream of the first auxiliary roller 2. A plurality of embossed pairs 420 are fixedly arranged on the roller surface of the second auxiliary roller 4. The plurality of embossed pairs 420 are used to cooperate with the corresponding plurality of embossed members 340 to form a plurality of embossed surfaces on the first fiber layer. It can be understood that the arrangement of the plurality of embossed pairs 420 on the second auxiliary roller 4 corresponds to the plurality of embossed members 340. The matching gap between the second auxiliary roller 2 and the main roller 3 can be adjusted according to the material and thickness of the first fiber layer and / or the influence of the temperature on the two rollers on the first fiber layer.

[0067] In this embodiment, the embossing member 340 includes at least one embossing pin, and the embossing counter member 420 includes a plurality of embossing grooves arranged correspondingly. The outer diameter of the embossing pin is smaller than the inner diameter of the embossing groove so that the embossing pin can extend into the embossing groove. The height of the embossing pin is smaller than or equal to the depth of the embossing groove, so that the embossing pin and the embossing groove are easy to engage, and the embossing pin is not easy to break when adjusting the matching clearance.

[0068] Continue to refer to Figure 3B , a surface 344 of the embossing pin 340 that faces away from the main roller 2 is provided with a central recess 342. The projection of the central recess 342 on the surface 344 is located within the surface 344. Providing the central recess 342 at the center position of the surface 344 reduces the area of ​​the embossed surface, thereby reducing the hardening area and increasing the softness and air permeability of the composite fiber layer without affecting the three-dimensionality of the composite fiber layer. In the present embodiment, there is no specific restriction on the shape of the central recess 342, as long as the central recess 342 can reduce the area of ​​the embossed surface and does not affect the shaping of the embossed pattern. It should be understood that the surface 344 of the embossing pin 340 of the present application that faces away from the main roller 2 may also have other convex-concave patterns, as long as the convex-concave pattern reduces the embossed area.

[0069] In addition, it should be noted that, for the cooperation between the second auxiliary roller 4 and the main roller 3 in this embodiment, the cooperation gap refers to the distance between the roller surface S1 of the main roller 3 and the surface S5 of the embossed pair 420 of the second auxiliary roller 4 closest to the roller surface S1 facing the main roller 3. It can be understood that the cooperation gap here can also refer to the distance between the bottom surface of the embossing groove of the main roller 3 and the surface 344 of the embossing pin when rolling the first fiber layer. Usually, the cooperation gap between the second auxiliary roller 4 and the main roller 3 is slightly larger than the thickness of the first fiber layer.

[0070] In a preferred embodiment, the matching gap between the main roller 3 and the first auxiliary roller 2 is smaller than the matching gap between the main roller 3 and the second auxiliary roller 4. In this way, the hole-opening effect during punching can be ensured while the embossing effect can be ensured.

[0071] Continue to view Figure 1The second fiber layer feeding mechanism 6 is used to sequentially feed the second fiber layer between the main roller 3 and the ultrasonic bonding mechanism 5 and the thermal bonding mechanism 9 to combine and bond the first fiber layer and the second fiber layer. In this embodiment, the configuration of the second fiber layer feeding mechanism 6 is similar to that of the first fiber layer feeding mechanism 7, and will not be described in detail here.

[0072] It should be noted that although a combination of an ultrasonic bonding mechanism 5 and a thermal bonding mechanism 9 is used in this embodiment, those skilled in the art should know that the bonding mechanism may use at least one of a thermal bonding device, an adhesive bonding device or an ultrasonic bonding device, and is not limited to the method in this embodiment.

[0073] When the second fiber layer is fed in for compounding with the first fiber layer, since the embossed surface of the first fiber layer is on the outermost surface of the main roller 3, i.e., the outer surface S2 of the main roller, the embossed part 340 cooperates with the ultrasonic bonding mechanism 5 and the thermal bonding mechanism 9 to press the first fiber layer and the second fiber layer at the embossed surface, so that the ultrasonic bonding mechanism 5 and the thermal bonding mechanism 9 thermally bond the first fiber layer and the second fiber layer at the embossed surface to obtain a composite fiber layer.

[0074] The composite fiber layer continues to be fed out by the main roller 3 and is transported to the forming cloth winding device 8 via a plurality of cloth guide wheels 1 .

[0075] In another embodiment, the device also includes a temperature regulating device, which is used to separately adjust the temperature of the roller surface of each roller, so that the roller surface temperature of the first auxiliary roller 2 is greater than or equal to the roller surface temperature of the second auxiliary roller 4, so that both punching and embossing can achieve better effects.

[0076] It should be pointed out that the opening member 320 provided on the roller surface and the step structure formed by the embossing member 340 and the roller surface S1 on the main roller 3 enable the main roller 3 to stably position and transport the fiber layer, so that the fiber layer has strong adhesion during transportation and is not easy to shift, so that a composite fiber layer with accurate embossing pattern and high opening quality can be obtained, thereby improving the yield rate. At the same time, the first fiber layer is first punched using the first auxiliary roller 2 and the main roller 3, the main roller 3 positions and transports the first fiber layer to the second auxiliary roller 4, and then the main roller 3 and the second auxiliary roller 4 are used to emboss the first fiber layer, and then the embossed surface is used to bond the first fiber layer and the second fiber layer to obtain the composite fiber layer of the present application. With this ingenious design of adding rollers, since the punching process and the embossing process are processed separately, the gap, temperature, etc. in the punching process and the embossing process can be adjusted to the optimal state according to actual needs without interfering with each other, thereby greatly improving the yield and production speed of the punching process and the embossing process. That is, overall, not only the yield of the composite fiber layer is improved, but also its production speed is improved, and the life of the equipment is extended. The inventor found through research and experiments that the yield of the composite fiber layer manufactured by the device of the present application can reach 92%, and the rotation speed of the roller is increased to at least 62 meters / minute. At the same time, due to the good positioning of the fiber layer on the device provided by the present application, the width range of the roller can be expanded to 800mm-1200mm, thereby further increasing the production efficiency of the composite fiber layer.

[0077] Next, please combine Figure 3C See also Figure 2 , Figure 2 The embodiment shown is Figure 1 The difference is that Figure 2 A third auxiliary roller 10 and a third fiber layer feeding mechanism 11 are also provided. The third auxiliary roller 10 is configured to cooperate with the main roller 2 and is disposed upstream of the first auxiliary roller 2. A plurality of second opening pairs 1020 are provided on the roller surface of the third auxiliary roller 10. The plurality of second opening pairs 1020 are used to cooperate with the corresponding opening members 322 to form a plurality of second openings on the third fiber layer.

[0078] In this embodiment, the third fiber layer feeding mechanism 11 is used to feed the third fiber layer between the main roller 2 and the third auxiliary roller 10. In this embodiment, the configuration of the third fiber layer feeding mechanism 11 is similar to the first fiber layer feeding mechanism 7, and will not be described in detail here. It should be noted that the ultrasonic bonding mechanism 5 and the thermal bonding mechanism 9 here bond the first fiber layer and the third fiber layer together with the second fiber layer.

[0079] Please refer to Figure 4A-4D , Figure 4A-4DThe diagram shows composite fiber layers with different patterns and made of fiber layers of different materials, which are manufactured under different manufacturing conditions using the composite fiber layer manufacturing device provided by each exemplary embodiment of the present application.

[0080] Specifically, Figure 4A FIG. 3 shows a pattern of a composite fiber layer. In this embodiment, each opening member 320 includes 13 opening needles 322, and the opening needles 322 are arranged in a snowflake shape to form a Figure 4A Each embossing member 340 includes three rhombus-shaped embossing pins with a common vertex, thereby forming a Figure 4A The embossed pattern is composed of three diamond-shaped embossed surfaces 24. In this embodiment, the composite fiber layer is a double-layer composite fiber layer, the first fiber layer uses a single hydrophilic material with a gram weight of 23 grams per square meter and a thickness of 0.35 mm, and the second fiber layer uses a multiple hydrophilic material with a gram weight of 18 grams per square meter and a thickness of 0.25 mm. In addition, the effective width of the roller is 1200 mm, the rotation speed of the roller is 60 meters per minute, the roller surface temperature of the first auxiliary roller 2 is 80°C, the roller surface temperature of the main roller 3 is 95°C, and the roller surface temperature of the second auxiliary roller 4 is 60°C. The bonding temperature of the thermal bonding mechanism 9 is 110°C, and the bonding strength is 0.8N. The matching clearance between the main roller 3 and the first auxiliary roller 2 is 0.4 mm, and the matching clearance between the second auxiliary roller 4 and the main roller 3 is 0.5 mm.

[0081] Figure 4B FIG. 3 shows another pattern of the composite fiber layer. In this embodiment, each opening member 320 includes five opening needles 322, and the opening needles 322 are arranged in a cross shape to form a Figure 4B Each embossing member 340 includes an embossing pin formed by two axially symmetrical concave curves, thereby forming Figure 4B The embossed pattern is composed of two axisymmetric concave curve-shaped embossed surfaces 24. In this embodiment, the composite fiber layer is a double-layer composite fiber layer, the first fiber layer is made of weakly hydrophilic material, with a gram weight of 21 g / m2 and a thickness of 0.3 mm, and the second fiber layer is made of single hydrophilic material, with a gram weight of 16 g / m2 and a thickness of 0.2 mm. In addition, the effective width of the roller is 1200 mm, the rotation speed of the roller is 55 m / min, the roller surface temperature of the first auxiliary roller 2 is 75°C, the roller surface temperature of the main roller 3 is 90°C, and the roller surface temperature of the second auxiliary roller 4 is 55°C. The bonding temperature of the thermal bonding mechanism 9 is 100°C, and the bonding strength is 1.7N. The matching clearance between the main roller 3 and the first auxiliary roller 2 is 0.35 mm, and the matching clearance between the second auxiliary roller 4 and the main roller 3 is 0.45 mm.

[0082] Figure 4CFIG. 3 shows another pattern of the composite fiber layer. In this embodiment, each opening member 320 includes 7 opening needles 322, and the opening needles 322 are arranged in a hexagonal shape to form a Figure 4C Each embossing member 340 includes wedge-shaped embossing pins arranged in a cross shape, thereby forming Figure 4C The embossed pattern is composed of a wedge-shaped embossed surface 24 arranged in a cross shape. In this embodiment, the composite fiber layer is a double-layer composite fiber layer, the first fiber layer is made of cotton fiber material, the gram weight is 35 grams per square meter, and the thickness is 0.5mm, and the second fiber layer is made of multiple hydrophilic materials, the gram weight is 15.5 grams per square meter, and the thickness is 0.2mm. In addition, the effective width of the roller is 1200mm, the rotation speed of the roller is 65 meters per minute, the roller surface temperature of the first auxiliary roller 2 is 100°C, the roller surface temperature of the main roller 3 is 120°C, and the roller surface temperature of the second auxiliary roller 4 is 95°C. The ultrasonic bonding mechanism 5 performs bonding, and the bonding strength is 1.0N. The matching clearance between the main roller 3 and the first auxiliary roller 2 is 0.56mm, and the matching clearance between the second auxiliary roller 4 and the main roller 3 is 0.58mm.

[0083] Figure 4D 3 shows another pattern of the composite fiber layer. In this embodiment, each opening member 320 includes 7 opening needles 322. Each embossing member 340 includes wedge-shaped embossing pins arranged in a cross shape, thereby forming Figure 4D The embossed pattern of the winter type is composed of the wedge-shaped embossed surface 24 arranged in a cross shape. In this embodiment, the composite fiber layer is a three-layer composite fiber layer, the first fiber layer adopts a weak multi-philic material, the gram weight is 15 grams per square meter, and the thickness is 0.18mm, the second fiber layer adopts a strong single hydrophilic material, the gram weight is 13.5 grams per square meter, the thickness is 0.16mm, and the third fiber layer adopts a perforated PE film, the gram weight is 17 grams per square meter, and the thickness is 0.2mm. In addition, the effective width of the roller is 1200mm, the rotation speed of the roller is 62 meters per minute, the roller surface temperature of the first auxiliary roller 2 is 80°C, the roller surface temperature of the main roller 3 is 100°C, and the roller surface temperature of the second auxiliary roller 4 is 80°C. The ultrasonic bonding mechanism 5 is bonded, and the bonding strength is 1.8N. The matching clearance between the main roller 3 and the first auxiliary roller 2 is 0.41mm, and the matching clearance between the second auxiliary roller 4 and the main roller 3 is 0.51mm.

[0084] Please refer to the following Figures 5A-5C , Figure 5A for Figure 1 A schematic top view of a double-layer composite fiber layer formed by the manufacturing device shown, Figure 5B for Figure 5A The schematic cross-sectional view of the double-layer composite fiber layer at the FF line is shown. Figure 5C for Figure 5B The cross-sectional schematic diagram shown is a partial enlarged view at point I.

[0085] Please refer to Figure 5A , Figure 5A The top view of a double-layer composite fiber layer of an embodiment of the present application is shown. Each of the multiple embossed parts 340 is composed of three rhombus-shaped embossing pins with a common vertex. Correspondingly, an embossed surface 24 with a corresponding pattern is formed on the composite fiber layer, that is, the pattern of the embossed surface is composed of three rhombuses with a common vertex. Each rhombus-shaped embossed surface (or bonding surface) extends along the periphery of the rhombus. Since a central concave portion is provided at the center of the top surface of the embossing pin, Figure 5A A bulge 22 is formed at the center of each rhombus in the embossed surface 24, and a cavity is formed in the bulge 22, thereby improving the air permeability and softness of the composite fiber layer. A plurality of openings 23 are formed outside the rhombus formed by the embossed surface 24.

[0086] Please combine Figure 5C Reference Figure 5B ,exist Figure 5B In the cross-sectional view of FIG. 2 , the lowest fiber layer is the second fiber layer 26. The upper fiber layer is the first fiber layer 21. Please continue to refer to FIG. Figure 5C The bulge 22 is located between the two larger bulges. Both ends of the bulge 22 extend downward to the embossed surface 24, where the first fiber layer 21 and the second fiber layer 26 are bonded to each other. A first opening 23 opening downward is formed on the top surface of the bulge formed by the first fiber layer 21.

[0087] Please refer to the following Figures 6A-6C , Fig. 6A for Figure 2 A schematic top view of a three-layer composite fiber layer formed by the manufacturing device shown, Figure 6B for Fig. 6A The schematic cross-sectional view of the three-layer composite fiber layer at the HH line is shown. Figure 6C for Figure 6B The cross-sectional schematic diagram shown is a partial enlarged view at II.

[0088] Please refer to Fig. 6A , Fig. 6A The top view of three composite fiber layers of an embodiment of the present application is shown. Each of the multiple embossing parts 340 is composed of three rhombus-shaped embossing pins with a common vertex. Correspondingly, an embossed surface 24 with a corresponding pattern is formed on the composite fiber layer, that is, the pattern of the embossed surface is composed of three rhombuses with a common vertex. Each rhombus-shaped embossed surface (or bonding surface) extends along the periphery of the rhombus. Since a central concave portion is provided at the center of the top surface of the embossing pin, Fig. 6A The center of each rhombus in the embossed surface 24 has a bulge 28, so that the composite fiber layer has good air permeability and softness. A plurality of openings 25 are formed outside the rhombus formed by the embossed surface 24.

[0089] Please combine Figure 6CReference Figure 6B ,exist Figure 6B In the cross-sectional view of FIG. 2 , the lowest fiber layer is the second fiber layer 26. The middle fiber layer is the first fiber layer 21. The upper fiber layer is the third fiber layer 27. Please continue to refer to FIG. Figure 6C , the bulge 28 is located between the two bulges. Both ends of the bulge 28 extend downward to the embossed surface 24, where the first fiber layer 21, the second fiber layer 26 and the third fiber layer 27 are bonded to each other. A second opening 25 opening downward is formed on the top surface of the bulge formed by the third fiber layer 27. A first opening 23 opening downward is provided on the top surface of the bulge formed by the first fiber layer 21 at a position corresponding to the second opening 25.

[0090] Please refer to Figure 7 , Figure 7 This is a flow chart of a method for manufacturing a composite fiber layer according to an embodiment of the present application. The method comprises the following steps:

[0091] Step S100, providing a manufacturing device for a composite fiber layer according to any one of the above embodiments;

[0092] Step S120: the first fiber layer feeding mechanism feeds the first fiber layer between the main roller and the first auxiliary roller, and the main roller and the first auxiliary roller rotate in opposite directions and cooperate with each other to form the plurality of first openings on the first fiber layer;

[0093] Step S140, the main roller uses the plurality of openings to position and convey the first fiber layer, and conveys the first fiber layer between the main roller and the second auxiliary roller, the main roller and the second auxiliary roller rotate in opposite directions to each other, and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer;

[0094] Step S160, the main roller uses the plurality of openings to position and convey the first fiber layer, and conveys the first fiber layer between the main roller and the bonding mechanism, the second fiber layer conveying mechanism conveys the second fiber layer between the main roller and the bonding mechanism, and the bonding structure bonds the first fiber layer and the second fiber layer to form a composite fiber layer;

[0095] Step S180: the main roller uses the plurality of openings to position and convey the composite fiber layer, and delivers the composite fiber layer to roll up the forming cloth.

[0096] Figure 8 This is a flow chart of a method for manufacturing a composite fiber layer according to another embodiment of the present application. The method comprises the following steps:

[0097] Step S200, providing a manufacturing device for the composite fiber layer of the above embodiment;

[0098] Step S220, the third fiber layer feeding mechanism feeds the third fiber layer between the main roller and the third auxiliary roller, and the main roller and the third auxiliary roller rotate in opposite directions and cooperate with each other to form the plurality of second openings on the third fiber layer;

[0099] Step S240, the main roller uses the plurality of opening members to position and convey the third fiber layer, and feeds the third fiber layer between the main roller and the first auxiliary roller, and the first fiber layer feeding mechanism also feeds the first fiber layer between the main roller and the first auxiliary roller, and the main roller and the first auxiliary roller rotate in opposite directions and cooperate with each other to form the plurality of first openings on the first fiber layer;

[0100] Step S260, the main roller uses the plurality of opening members to position and convey the first fiber layer and the third fiber layer, and conveys the first fiber layer and the third fiber layer between the main roller and the second auxiliary roller, and the main roller and the second auxiliary roller rotate in opposite directions and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer and the third fiber layer;

[0101] Step S280, the main roller uses the plurality of opening members to position and convey the first fiber layer and the third fiber layer, and conveys the first fiber layer and the third fiber layer between the main roller and the bonding mechanism, the second fiber layer conveying mechanism conveys the second fiber layer between the main roller and the bonding mechanism, and the bonding structure bonds the first fiber layer and the third fiber layer to the second fiber layer to form a composite fiber layer;

[0102] Step S290: the main roller uses the plurality of openings to position and convey the composite fiber layer, and delivers the composite fiber layer to roll up the forming cloth.

[0103] Figure 7 and Figure 8 The features of each element and step in the provided method for manufacturing the composite fiber layer have been described in detail in the aforementioned embodiments and will not be repeated here.

[0104] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0105] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A manufacturing device for a composite fiber layer, wherein the composite fiber layer comprises a double-layer composite fiber layer, and the double-layer composite fiber layer is obtained by bonding a first fiber layer and a second fiber layer, wherein: The first fiber layer has perforations and embossing, and the manufacturing device comprises: A main roller, wherein a roller surface of the main roller is provided with a plurality of embossed parts and a plurality of opening parts; A first auxiliary roller, configured to cooperate with the main roller, wherein a plurality of first opening pairs are provided on a roller surface of the first auxiliary roller, and the plurality of first opening pairs are used to cooperate with the plurality of opening members to form a plurality of first openings on the first fiber layer; A first fiber layer feeding mechanism, used for feeding the first fiber layer between the main roller and the first auxiliary roller; A second auxiliary roller, arranged to cooperate with the main roller and arranged downstream of the first auxiliary roller, a roller surface of the second auxiliary roller is provided with a plurality of embossed pairs, the plurality of embossed pairs are used to cooperate with the plurality of embossed members to form a plurality of embossed surfaces on the first fiber layer; a bonding mechanism, for bonding the first fiber layer and the second fiber layer; and A second fiber layer feeding mechanism, used for feeding the second fiber layer between the main roller and the bonding mechanism; The embossing member includes a plurality of embossing pins, and the embossing counter-member includes a plurality of corresponding embossing grooves, the outer diameter of the embossing pin is smaller than the inner diameter of the embossing groove so that the embossing pin can extend into the embossing groove, and the height of the embossing pin is smaller than or equal to the depth of the embossing groove; A central recess is provided on the surface of the embossing pin facing away from the main roller, and a projection of the central recess on the surface is located within the surface; The device also includes: a third auxiliary roller, arranged to cooperate with the main roller and arranged upstream of the first auxiliary roller, a roller surface of the third auxiliary roller is provided with a plurality of second opening pairs, the plurality of second opening pairs are used to cooperate with the plurality of opening members to form a plurality of second openings on the third fiber layer; and A third fiber layer feeding mechanism, used for feeding the third fiber layer between the main roller and the third auxiliary roller; The bonding mechanism is used to bond the first fiber layer and the third fiber layer with the second fiber layer, and the second fiber layer feeding mechanism is used to feed the second fiber layer between the main roller and the bonding mechanism to bond with the first fiber layer and the third fiber layer.

2. The device according to claim 1, characterized in that The fitting clearance between the main roller and the first auxiliary roller is smaller than the fitting clearance between the main roller and the second auxiliary roller.

3. The device according to claim 1, characterized in that The device further comprises a temperature regulating device, and the temperature regulating device is used to regulate the temperature of the roller surface of each roller so that the roller surface temperature of the first auxiliary roller is greater than or equal to the roller surface temperature of the second auxiliary roller.

4. The device according to claim 1, characterized in that Each of the plurality of opening members includes at least one opening needle fixed on the roller surface of the main roller; each of the plurality of first opening pairs includes an opening boss fixed on the roller surface of the first auxiliary roller, and the surface of the opening boss facing away from the first auxiliary roller is provided with at least one opening matching with the at least one opening needle, and the height of the at least one opening needle is less than or equal to the depth of the at least one matching opening.

5. The device according to claim 1, characterized in that The bonding mechanism includes at least one of a thermal bonding device, an adhesive bonding device or an ultrasonic bonding device.

6. A method for manufacturing a composite fiber layer, comprising: Providing a manufacturing device for a composite fiber layer according to any one of claims 1 to 4; The first fiber layer feeding mechanism feeds the first fiber layer between the main roller and the first auxiliary roller, and the main roller and the first auxiliary roller rotate in opposite directions to each other and cooperate with each other to form the plurality of first openings on the first fiber layer; The main roller uses the plurality of openings to position and convey the first fiber layer, and conveys the first fiber layer between the main roller and the second auxiliary roller, wherein the main roller and the second auxiliary roller rotate in opposite directions to each other and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer; The main roller uses the plurality of openings to position and convey the first fiber layer, and conveys the first fiber layer between the main roller and the bonding mechanism, the second fiber layer conveying mechanism conveys the second fiber layer between the main roller and the bonding mechanism, and the bonding structure bonds the first fiber layer and the second fiber layer to form a composite fiber layer; The main roller uses the plurality of openings to position and convey the composite fiber layer, and delivers the composite fiber layer to roll up the forming cloth; The third fiber layer feeding mechanism feeds the third fiber layer between the main roller and the third auxiliary roller, and the main roller and the third auxiliary roller rotate in opposite directions and cooperate with each other to form the plurality of second openings on the third fiber layer; The main roller uses the plurality of openings to position and convey the third fiber layer, and feeds the third fiber layer between the main roller and the first auxiliary roller, and the first fiber layer feeding mechanism also feeds the first fiber layer between the main roller and the first auxiliary roller, and the main roller and the first auxiliary roller rotate in opposite directions and cooperate with each other to form the plurality of first openings on the first fiber layer; The main roller positions and conveys the first fiber layer and the third fiber layer by using the plurality of opening members, and conveys the first fiber layer and the third fiber layer between the main roller and the second auxiliary roller, and the main roller and the second auxiliary roller rotate in opposite directions and cooperate with each other to form a plurality of embossed surfaces on the first fiber layer and the third fiber layer; The main roller uses the plurality of openings to position and convey the first fiber layer and the third fiber layer, and conveys the first fiber layer and the third fiber layer between the main roller and the bonding mechanism, the second fiber layer conveying mechanism conveys the second fiber layer between the main roller and the bonding mechanism, and the bonding structure bonds the first fiber layer and the third fiber layer to the second fiber layer to form a composite fiber layer; The main roller positions and conveys the composite fiber layer by using the plurality of openings, and delivers the composite fiber layer to roll up the forming cloth.

7. A composite fiber layer formed by the device according to any one of claims 1 to 4.

8. An absorbent product made of at least the composite fiber layer according to claim 6.

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