A method for finishing a polymer hydrophilic-hydrophobic gradient of a breast pad of a breast bra

Abstract

The application discloses a polymer hydrophilic-hydrophobic gradient finishing method for a breast wetting layer of a breast bra, and belongs to the field of polymer finishing of functional textiles. In order to solve the problems of horizontal diffusion, outside liquid permeation, finishing layer attenuation after washing and residue migration when emulsion and sweat locally leak, the application adopts a same-skeleton hydrophilic, transition and hydrophobic finishing dispersion, forms a planar pattern of a hydrophilic micro dot array-transition ring-hydrophobic guard ring on a cup wetting layer, and realizes the technical effects of local introduction, outside liquid resistance, interface washing resistance and migration control through bidirectional penetration, incomplete pre-drying, limited overlap in the middle section, co-curing and post-extraction to form a thickness gradient.

Description

Technical Field

[0001] This invention relates to the field of polymer finishing of functional textiles, and more particularly to a polymer hydrophilic-hydrophobic gradient finishing method for the moisture-absorbing layer of a nursing bra. Background Technology

[0002] Nursing bras' cups need to absorb leaked lotion and sweat, striking a balance between skin-friendly comfort, moisture wicking, and protection against staining outer clothing. Existing moisture-wicking layers typically employ an overall hydrophilic finish, allowing liquid to easily diffuse laterally along the skin-contacting surface and fiber layer, reaching the cup edges or outer surface. When an overall hydrophobic finish is used, liquid may stagnate on the skin-contacting side, resulting in dampness and stuffiness.

[0003] Existing localized finishing processes may lack stable registration between planar patterns and thickness structures. Interfaces between different finishing polymers are prone to detachment under repeated washing and shearing, leading to a decrease in hydrophilicity-hydrophobicity gradients. If the finishing agent is not fully cured or removed by subsequent washing, migratory residues may migrate towards the skin-contact side. Therefore, it is necessary to simultaneously control the planar liquid-contacting position, the penetration front in the thickness direction, the interfacial overlap and co-curing, and the extraction release endpoint.

[0004] Therefore, there is a need for a polymer hydrophilic-hydrophobic gradient finishing method for the moisture-absorbing layer of nursing bras that can overcome the shortcomings of the existing technology. Summary of the Invention

[0005] One objective of this invention is to propose a polymer hydrophilic-hydrophobic gradient finishing method for the absorbent layer of a nursing bra. Addressing the problems of existing technologies where overall hydrophilic finishing easily leads to lateral diffusion and external liquid permeation, and overall hydrophobic finishing easily leads to moisture retention and re-wetting, as well as the issues of interface detachment and residue migration after washing of various finishing layers, this invention proposes a method to prepare hydrophilic, transitional, and hydrophobic finishing dispersions using the same water-dispersible and crosslinkable polymer as a common framework. This forms a hydrophilic microarray, transitional ring, and hydrophobic protective ring on the skin-contact surface, creating alternating penetration areas from the skin-contact surface and the outer surface. After incomplete pre-drying, the transitional dispersion is applied between the two leading edges, aligning the planar pattern with the continuous limited overlapping area. The entire process is then co-cured and water-extracted until the migration index reaches the release limit. This invention effectively limits lateral diffusion on the skin, reduces external liquid permeation, improves the wash resistance of the overlapping interface, and controls migratable residues.

[0006] This invention provides a method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient, comprising:

[0007] S1. Provides a fiber moisture-absorbing layer and a hydrophilic finishing dispersion, a transition finishing dispersion and a hydrophobic finishing dispersion with the same crosslinkable polymer backbone, wherein the water contact angle of the three cured layers increases sequentially.

[0008] S2. The hydrophilic finishing dispersion is used to form a hydrophilic microarray in the nipple-corresponding area of ​​the skin-contacting surface of the fiber moisture-absorbing layer, and the transition finishing dispersion and the hydrophobic finishing dispersion are used in sequence to form a transition ring and a hydrophobic protective ring around it.

[0009] S3. A hydrophilic finishing dispersion is applied from the skin-adhering surface to form a first penetration region extending to the first penetration front, and a hydrophobic finishing dispersion is applied from the opposite outer surface to form a second penetration region extending to the second penetration front, so that the two penetration fronts are spaced apart, and the two penetration fronts are partially pre-baked to stop macroscopic flow and retain the reaction end groups.

[0010] S4. Apply a transitional dispersion between the two penetration fronts, so that it overlaps with the first penetration region and the second penetration region in thickness, forming a continuous limited overlap region that does not extend to the skin-contact surface and the outer surface, and make the projections of the hydrophilic micro-lattice, the transition ring and the hydrophobic protective ring along the thickness direction at least partially overlap with the first penetration region, the continuous limited overlap region and the second penetration region.

[0011] S5. Overall baking, so that the polymers of the three finishing dispersions form a co-curing network between each other and with the fiber surface, followed by water extraction until the migratable residue index is not greater than the corresponding preset migration release limit, to obtain a gradient finishing moisture-absorbing layer.

[0012] Optionally, S1 includes: before using the fiber absorbent layer as a finishing substrate, cleaning the surface of the fiber absorbent layer, and performing one of plasma activation, corona activation and aqueous coupling agent activation based on the wetting tension test results of the fiber surface after cleaning, so that the activated wetting tension reaches a preset dispersion spreading threshold.

[0013] The common backbone is one of aliphatic polyurethane and polyurethane-acrylic acid copolymer, and the three finishing dispersions have the same crosslinking end groups that can react with each other and react with the fiber surface.

[0014] The hydrophilic dispersion has a higher molar percentage of hydrophilic side chains than the non-fluorinated alkylsiloxane side chains. The transition dispersion contains both hydrophilic and non-fluorinated alkylsiloxane side chains. The hydrophobic dispersion has a higher molar percentage of non-fluorinated alkylsiloxane side chains than the hydrophilic side chains.

[0015] Optionally, S2 includes: setting the duty cycle of the hydrophilic micro-array to 5% to 35%, setting the equivalent diameter of a single hydrophilic micro-dot to 0.1 mm to 2 mm, and maintaining water vapor channels between adjacent hydrophilic micro-dots that are not continuously covered by the hydrophilic dispersion.

[0016] A transition ring is formed starting from the outer boundary of the hydrophilic micro-array, and a hydrophobic protective ring is formed starting from the outer boundary of the transition ring. The hydrophobic protective ring is composed of hydrophobic sections spaced apart along the circumference, so that the hydrophobic protective ring does not block the water vapor channel.

[0017] Optionally, S3 includes: on a calibration sheet having the same material and thickness as the fiber moisture-absorbing layer, changing the unit area liquid application rate, pressure difference, and pressure difference holding time for the hydrophilic finishing dispersion, and establishing a first calibration relationship between the unit area liquid application rate, pressure difference, and pressure difference holding time of the hydrophilic finishing dispersion and the position of the first penetration front.

[0018] To address the issue of varying the unit area application rate, pressure differential, and pressure differential holding time of the hydrophobic treated dispersion, a second calibration relationship is established between the unit area application rate, pressure differential, and pressure differential holding time of the hydrophobic treated dispersion and the position of the second penetration front.

[0019] The midpoints of the first and second front target intervals, set according to the fiber moisture-absorbing layer thickness ratio in the product design, are respectively determined as the target positions of the first and second penetration fronts. The first calibration relationship is queried based on the target position of the first penetration front, and the second calibration relationship is queried based on the target position of the second penetration front. The unit area liquid application rate, pressure difference, and pressure difference holding time of the two types of finishing dispersions are determined respectively, so that an interval is reserved between the two penetration fronts for receiving the transition finishing dispersion.

[0020] Furthermore, the endpoint of the incomplete pre-drying is determined by the displacement of the front edge and the amount of reactive end groups retained: after maintaining the same pressure difference as when the corresponding penetration front edge is formed for 30 seconds, the displacement of the corresponding penetration front edge does not exceed 5% of the thickness of the fiber moisture-absorbing layer, and the reactive end group characteristic signal at the corresponding penetration front edge after pre-drying is not less than 20% of the corresponding characteristic signal before pre-drying, the incomplete pre-drying ends.

[0021] Optionally, S4 includes: performing functional group mapping using a witness sheet or a cross-sectional sample obtained from a fiber hygroscopic layer after the formation of the two penetration fronts to determine the spacing position of the two penetration fronts;

[0022] The product design sets the range according to the fiber moisture-absorbing layer thickness ratio and can accommodate two overlapping thicknesses as the target range to be applied. When the order of the two penetration fronts is opposite to S3 or the interval position does not fall into the target range to be applied, stop applying the transition finishing dispersion, adjust the unit area liquid application amount, pressure difference or pressure difference holding time corresponding to the hydrophilic finishing dispersion or hydrophobic finishing dispersion, and re-measure the interval position of the two penetration fronts.

[0023] When the interval position falls within the target application range, the amount of liquid applied per unit area and the applied pressure difference of the transitional dispersion are controlled according to the interval position, so that the transitional dispersion and the portion of the first penetration area near the first penetration front and the portion of the second penetration area near the second penetration front respectively form a thickness overlap. The total thickness of the two thickness overlaps is 5% to 30% of the thickness of the fiber moisture-absorbing layer, and the continuous limited overlap area is kept apart from the skin-contact surface and the outer surface.

[0024] Optionally, S5 includes: performing segmented pre-drying before overall roasting, wherein the segmented pre-drying includes setting corresponding pre-drying temperatures and pre-drying times according to the water evaporation rates of the hydrophilic treatment dispersion, the transitional treatment dispersion, and the hydrophobic treatment dispersion, so that the three treatment dispersions retain the reaction end groups before overall roasting.

[0025] The temperature and time of the overall baking are determined according to the cross-linking reaction window of the common skeleton, so that the cross-linking conversion rate of the three polymers in the continuous limited overlapping area reaches the preset curing release value, and the ratio of the moisture permeability per unit area after baking to that before baking is within the closed range of the preset retention ratio to 1.

[0026] Furthermore, the water extraction adopts a continuous water washing method, and the extract is collected at a set sampling interval, and at least one of the total organic carbon, non-volatile matter content and target residue content is selected as the migration index.

[0027] Based on the migration limit of the skin-penetrating material corresponding to each selected migration indicator, a preset migration release limit with the same dimension as the migration indicator is set.

[0028] Water extraction ends and the gradient-finding moisture-absorbing layer is shaped when the detection values ​​of all selected migration indicators at three consecutive sampling points are not greater than their respective preset migration release limits.

[0029] Furthermore, it also includes a cross-section and planar feedback step: preparing uniformly cured images of hydrophilic-finished dispersion, transition-finished dispersion and hydrophobic-finished dispersion respectively, obtaining the reference feature signals of the corresponding side chains on the uniformly cured images of hydrophilic-finished dispersion and hydrophobic-finished dispersion, determining the first frontal edge determination threshold and the second frontal edge determination threshold according to the product of each reference feature signal and the first preset ratio, and determining the hydrophilic coexistence threshold and the hydrophobic coexistence threshold according to the product of each reference feature signal and the second preset ratio respectively.

[0030] Distribution curves of hydrophilic side chain characteristic signals and non-fluorinated alkylsiloxane side chain characteristic signals are obtained along the thickness direction of the gradient-sorted moisture-absorbing layer. Starting from the skin-contact surface, the first pair of adjacent sampling points where the hydrophilic side chain characteristic signal is located on both sides of the first front determination threshold are found, and linear interpolation is performed between the first pair of adjacent sampling points to determine the first penetration front. Starting from the outer surface, the first pair of adjacent sampling points where the non-fluorinated alkylsiloxane side chain characteristic signal is located on both sides of the second front determination threshold are found, and linear interpolation is performed between the first pair of adjacent sampling points to determine the second penetration front.

[0031] The connected interval located between two penetration fronts, with hydrophilic side chain characteristic signals not less than the hydrophilic coexistence threshold and non-fluorinated alkylsiloxane side chain characteristic signals not less than the hydrophobic coexistence threshold, is defined as the coexistence interval. When there are multiple coexistence intervals, the coexistence interval with the highest continuous thickness value is selected as the continuous limited overlap region. When the continuous thickness values ​​of two or more coexistence intervals are tied for first place, the coexistence interval with the highest coordinate value from the starting position of the skin surface is selected as the continuous limited overlap region. When there are no coexistence intervals, an invalid cross-section marker is generated and the generation of adjustment amount is stopped.

[0032] Obtain the functional group distribution map or wettability distribution map of the skin-adhering surface. Identify the hydrophilic microarray, transition ring, hydrophobic protective ring and water vapor channels that are not continuously covered based on the pixel classification threshold determined by three uniform curing photos. Calculate the duty cycle of the hydrophilic microarray, the connectivity state of the water vapor channels, and the projection overlap ratio of the hydrophilic microarray, transition ring and hydrophobic protective ring with the first penetration area, the continuous limited overlap area and the second penetration area, respectively.

[0033] The target ranges of the front edge and overlap area set according to the fiber moisture-absorbing layer thickness ratio in the product design, as well as the target ranges of duty cycle, channel connectivity conditions and projection overlap ratio set according to the planar pattern, are used as corresponding targets. The measured results are compared with the corresponding targets.

[0034] Adjust at least one of the following based on the positional deviation in the thickness direction: liquid application rate per unit area, pressure difference, pressure difference holding time, and pre-drying time of the corresponding dispersion. Adjust at least one of the following based on the deviation of the planar pattern or projection overlap ratio: duty cycle of the hydrophilic microarray, droplet size, pattern application position, transition ring width, and hydrophobic protective ring width, in order to finish the subsequent fiber moisture-absorbing layer.

[0035] Furthermore, migration verification and wash resistance verification are performed on the finalized gradient finishing moisture-absorbing layer: an upper limit for extraction time and an upper limit for extraction water volume are set for water extraction. When either upper limit is reached, if the detection value of the selected migration index is still greater than its corresponding preset migration release limit, the migration verification result is marked as abnormal.

[0036] Complete at least 20 washing cycles according to the preset washing program, calculate the normalized correlation coefficient of the hydrophilic side chain characteristic signal distribution curve before and after washing, the normalized correlation coefficient of the non-fluorinated alkylsiloxane side chain characteristic signal distribution curve, the ratio of the position deviation of the continuous finite overlap area to the thickness of the fiber moisture-absorbing layer, and the ratio of the thickness of the continuous finite overlap area after washing to that before washing. Compare the four results with their respective wash resistance release limits. If any one of them does not meet the corresponding wash resistance release limit, the wash resistance verification result is marked as abnormal.

[0037] When the migration verification results are abnormal, adjust the corresponding crosslinking agent dosage according to the equivalent amount of the reactive end groups contained in each of the three finishing dispersions, and make the equivalent ratio of the reactive end groups of the three finishing dispersions within the preset co-curing equivalent ratio range. At the same time, adjust at least one of the following: water temperature, water flow rate per unit time, water exchange frequency, extraction time, and extraction water volume.

[0038] If the washability test results are abnormal, adjust at least one of the following: the thickness of the continuous limited overlapping area, the overall baking temperature, and the overall baking time;

[0039] The adjusted parameters were used to prepare the verification sample and the migration verification and wash resistance verification were repeated. The results of both verifications were not marked as abnormal as a safety constraint for subsequent recovery.

[0040] The beneficial effects of this invention are:

[0041] 1. Through the local planar structure of hydrophilic micro-lattice, transition ring and hydrophobic protective ring, liquid enters the moisture-absorbing layer from discrete contact points in the corresponding area of ​​the nipple, and the outer hydrophobic structure inhibits lateral liquid flow on the skin-contacting surface, while retaining water vapor channels that are not continuously covered.

[0042] 2. By forming alternating hydrophilic and hydrophobic penetration areas from the skin-contacting surface and the outer surface, and forming a continuous limited overlap area between the two leading edges that does not touch the two surfaces, the liquid introduction and the outer liquid blocking are coordinated along the thickness direction, and the transition area softens the abrupt change of the hydrophilic and hydrophobic interface.

[0043] 3. By using limited overlap co-curing of polymers with the same backbone and multi-index water extraction after baking, a continuous network is formed between the finished polymers and on the fiber surface, reducing the amount of residues that do not meet the migration limit from entering subsequent use stages. Attached Figure Description

[0044] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0045] Figure 1 This is a flowchart of the polymer hydrophilic-hydrophobic gradient finishing method for the moisture-absorbing layer of the nursing bra according to the present invention.

[0046] Figure 2 This is a flowchart of forming a continuous finite overlapping region in S4 of the present invention. Detailed Implementation

[0047] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0048] refer to Figures 1-2 A method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient, comprising:

[0049] S1. Provides a fiber moisture-absorbing layer and a hydrophilic finishing dispersion, a transition finishing dispersion and a hydrophobic finishing dispersion with the same crosslinkable polymer backbone, wherein the water contact angle of the three cured layers increases sequentially.

[0050] S2. The hydrophilic finishing dispersion is used to form a hydrophilic microarray in the nipple-corresponding area of ​​the skin-contacting surface of the fiber moisture-absorbing layer, and the transition finishing dispersion and the hydrophobic finishing dispersion are used in sequence to form a transition ring and a hydrophobic protective ring around it.

[0051] S3. A hydrophilic finishing dispersion is applied from the skin-adhering surface to form a first penetration region extending to the first penetration front, and a hydrophobic finishing dispersion is applied from the opposite outer surface to form a second penetration region extending to the second penetration front, so that the two penetration fronts are spaced apart, and the two penetration fronts are partially pre-baked to stop macroscopic flow and retain the reaction end groups.

[0052] S4. Apply a transitional dispersion between the two penetration fronts, so that it overlaps with the first penetration region and the second penetration region in thickness, forming a continuous limited overlap region that does not extend to the skin-contact surface and the outer surface, and make the projections of the hydrophilic micro-lattice, the transition ring and the hydrophobic protective ring along the thickness direction at least partially overlap with the first penetration region, the continuous limited overlap region and the second penetration region.

[0053] S5. Overall baking, so that the polymers of the three finishing dispersions form a co-curing network between each other and with the fiber surface, followed by water extraction until the migratable residue index is not greater than the corresponding preset migration release limit, to obtain a gradient finishing moisture-absorbing layer.

[0054] In this specific embodiment, S1 includes:

[0055] The material preparation system first reads the raw material batch number, substrate fiber composition, target thickness, areal density, pattern version and production date from the product process sheet. It then uses the fiber moisture-absorbing layer, hydrophilic finishing dispersion, transition finishing dispersion and hydrophobic finishing dispersion that are consistent with the product process sheet as the process input for this batch. If any of the raw material batch number, common skeleton batch number or pattern version is missing, the system keeps the conveying and liquid application valves closed and generates a batch record to be completed.

[0056] In this specific embodiment, the processing object is a polyester-viscose blended needle-punched fiber moisture-absorbing layer of the same batch with a thickness of 2.0 mm and a surface density of 180 g / m². Each cut piece is assigned a batch number, roll number, cut piece number, skin-contact surface identification and thickness measurement value according to the layout diagram. After being sprayed with deionized water, it is dried at 60 degrees Celsius until the mass change between two consecutive weighings is no more than 0.5%. Then it is equilibrated at 23±2 degrees Celsius and 50±5% relative humidity for 24 hours. The equilibrated thickness, surface density and skin-contact surface direction are written into the substrate batch record.

[0057] Before using the fiber absorbent layer as the finishing substrate, the surface is cleaned by spraying with deionized water and constant weight conditions as described above. The cleaned fiber absorbent layer is then activated by atmospheric pressure air plasma with a conveying speed of 8 m / min and a discharge power of 1.2 kW. The treatment energy is applied to the skin-contact surface and the outer surface. Within 5 minutes after activation, three 100 mm test lines are drawn along the warp and weft directions using a water-based test pen. The wettability of the test liquid film is considered valid if it does not shrink or break within 2 seconds.

[0058] Three dispersions were added dropwise at 0.10 mL onto the same batch of unactivated and different activated moisture-absorbing fiber layers. The minimum surface wetting tension required to form a non-shrinkage liquid film within 10 seconds after addition was measured. The sum of the upper limit of the minimum requirement of the three dispersions and the process margin of 2 mN / m was calibrated as the dispersion spreading threshold. The calibration value for this batch was 42 mN / m and was recorded in the activation parameter record. If two of the three test lines in any direction after cleaning and activation were lower than this threshold, the cut piece was returned to the plasma activation station and not allowed to enter the subsequent liquid application.

[0059] The hydrophilic, transitional, and hydrophobic dispersions all use hydroxyl-terminated aliphatic polyurethane-acrylic acid copolymers as a common backbone, and the surface energy is adjusted by polyethylene glycol side chains and fluorine-free alkylsiloxane side chains, respectively. The solid content of the three dispersions is adjusted to 12±0.5%, the pH is adjusted to 7.5±0.3, and a blocked polyisocyanate crosslinking agent is added so that the ratio of the isocyanate equivalent after the crosslinking agent is unblocked to the hydroxyl equivalent of each of the three dispersions is 0.95 to 1.05. The hydroxyl groups on the common backbone and the unblocked isocyanate groups constitute the same type of crosslinking end groups that can react with each other and react with the hydroxyl groups on the fiber surface.

[0060] Using the total amount of hydrophilic side chains and non-fluorinated alkylsiloxane side chains as the statistical benchmark, the molar percentage of hydrophilic side chains in the hydrophilic dispersion was set to 75% and the molar percentage of non-fluorinated alkylsiloxane side chains was set to 25%. In the transitional dispersion, the molar percentage of both types of side chains was set to 50%. In the hydrophobic dispersion, the molar percentage of hydrophilic side chains was set to 20% and the molar percentage of non-fluorinated alkylsiloxane side chains was set to 80%. The side chain percentage was double-checked based on the monomer feed amount and the nuclear magnetic resonance integral results. If any percentage exceeded the set value by ±3 percentage points, the batch of dispersions was isolated.

[0061] Three dispersions were coated onto the same batch of activated substrates and cured into uniform films under the same conditions. Static water contact angles were measured at 23°C using 2 μL of deionized water at 5 different measurement points. Continuous photography was taken at each measurement point, capturing the angle 5 seconds after the droplet was applied. The median angle was used as the water contact angle of the corresponding cured layer. The three cured layers must meet the following requirements: , The water contact angle of the hydrophilic dispersion solidified layer, expressed in degrees, is obtained from the median of five measuring points. In this specific embodiment, it is controlled between 35 and 55 degrees. The water contact angle of the solidified layer of the transitional dispersion is expressed in degrees. The measurement method is the same and the angle is controlled between 65 and 85 degrees. The water contact angle of the hydrophobic treated dispersion solidified layer is expressed in degrees. The measurement method is the same and controlled within 100 to 120 degrees.

[0062] The three dispersions that pass the side chain ratio and water contact angle tests are written into the same batch formulation record. The record must include at least the dispersion type, common skeleton batch number, molar ratio of the two side chains, solid content, pH, crosslinking end group equivalent ratio, water contact angle, and effective time. The application system uses the common skeleton batch number and effective time as the co-bonding to lock the three dispersions. If the co-bonding is inconsistent or any release test fails, the pattern application process of S2 is not allowed to be started.

[0063] In this specific embodiment, S2 includes:

[0064] The pattern application system reads the substrate batch record and formula record formed by S1, takes the nipple center mark of the nursing bra cut piece as the pattern origin, sets the target area of ​​the hydrophilic micro dot array as a circular area with a diameter of 40 mm, and applies the hydrophilic finishing dispersion from the skin-contact surface using a screen with an opening diameter of 600 micrometers. The liquid application is only performed when the plane offset between the screen positioning mark and the cut piece origin is no more than 0.5 mm.

[0065] The hydrophilic micro-dot array employs an equilateral triangular mesh arrangement, setting the equivalent diameter of a single micro-dot to 0.60 mm and the center-to-center spacing to 1.50 mm. Calculate the duty cycle of the hydrophilic micro-dots. This indicates the duty cycle of the hydrophilic micro-dots, a dimensionless percentage calculated based on the batch of imprint images and limited to 5% to 35%. This represents the number of complete hydrophilic micro-points identified within the target area, and is a dimensionless positive integer. Pi is a dimensionless, fixed mathematical constant. This represents the equivalent diameter calculated from the area of ​​a single micro-pixel, expressed in millimeters and limited to the range of 0.1 mm to 2 mm. The projected area of ​​the target region of the hydrophilic micro-dot array is expressed in square millimeters and is calculated from the target boundary in the material layout diagram.

[0066] Immediately after the screen is removed, a visible light imprint image with a resolution of 20 micrometers / pixel is acquired. The hydrophilic dispersion staining tracer channel is binarized with a fixed threshold. Splash connected regions with an area less than 20% of the target micro-dot area are removed and holes with an area less than 10% of the individual micro-dot area are filled. The corrected micro-dot contour, equivalent diameter, center coordinates and duty cycle are written into the dot matrix quality record. When the equivalent diameter or duty cycle exceeds the target range, the cut piece is isolated and the screen and squeegee pressure are adjusted.

[0067] Within the target area, non-hydrophilic micro-dot pixels are used to construct an eight-neighbor connectivity graph. A closed circle with a radius of one pixel, centered at the pattern origin and 20% of the target area's radius, is generated as the inner circle of the target area. The inner circle pixels are included according to the rule that the distance from the center of the circle to the pixel center is no greater than this radius and the difference from this radius is no more than half a pixel's diagonal. The outer boundary is the outermost pixel ring of the target circular area. All continuous non-hydrophilic micro-dot paths from the inner circle to the outer boundary of the target area are considered as candidate water vapor channels. If the inner circle is not closed after pixelation or there is no non-hydrophilic starting pixel on the inner circle, the piece is marked as having an invalid inner circle, and channel search is stopped. For the valid candidate set, candidate paths with a minimum width less than 0.30 mm are first deleted, and then arranged in descending order of minimum channel width. When the minimum widths are the same, ... Arrange the paths in ascending order of path length. When the minimum width and path length are the same, arrange them in ascending order of the polar angle of the path starting point relative to the pattern origin. Then, arrange the pixel coordinates of the path endpoints when the polar angles are the same in ascending order of their horizontal and vertical coordinates. Initialize the retention set to empty. Scan the candidate paths one by one according to the above sorting. Only add the current candidate path to the retention set if it does not share a bottleneck pixel with any path in the retention set. Stop scanning when the retention set reaches 6 paths. Record the paths in the retention set as water vapor channels that are not continuously covered by the hydrophilic dispersion. This specific embodiment requires the formation of 6 radial water vapor channels that do not share key pixels. If the number of retained paths is less than 6 after all candidate scans are completed, mark the piece as a pattern abnormality and do not apply it to the annular region.

[0068] Starting from the outer boundary of the hydrophilic microdot array, a concentric ring screen is used to apply a transitional dispersion. The width of the transition ring is set to 8 mm, and the radial alignment deviation between the ring screen and the outer boundary of the hydrophilic microdot array is limited to no more than 0.5 mm. For each released water vapor channel, a non-perforated radial notch is set on the transition ring screen, extending from the inner boundary to the outer boundary. The minimum width of the notch is set to 0.40 mm and is not less than the minimum width of the corresponding channel. The circumferential deviation between the center line of the notch and the center line of the water vapor channel outlet is no more than 1 degree. The inner boundary of the transition ring aligns with the outer boundary of the hydrophilic microdot array, but the water vapor channel remains continuous through the notch. The notch position also serves as the registration reference for the opening of the hydrophobic protective ring. The inner and outer diameters, ring width, notch boundary, and application batch number of the transition ring are recorded in the planar pattern.

[0069] Starting from the outer boundary of the transition ring, a hydrophobic finishing dispersion is applied. The hydrophobic protective ring consists of 12 arc-shaped hydrophobic sections spaced circumferentially. The central angle of each hydrophobic section is 20 degrees and a 10-degree opening is maintained between adjacent sections. The opening is aligned with the outlet of the identified water vapor channel so that the hydrophobic protective ring does not close the water vapor channel and does not form a closed cover around the hydrophilic micro-dot array. When the circumferential deviation between the center of the opening and the center of the corresponding channel exceeds 2 degrees, the subsequent finishing of the current piece is stopped.

[0070] For the six selected radial water vapor channels, record the channel start point, end point, minimum width, path length, transition ring notch center angle, corresponding hydrophobic guard ring opening center angle, and connectivity status. After applying the hydrophilic micro-point, transition ring, and hydrophobic section, re-perform the eight-neighbor connectivity determination. When any channel is covered by the transition ring section, delete the release mark of the piece. Based on the position of the blocked pixel relative to the notch boundary, move the corresponding non-opening notch of the next piece 1 degree in the opposite direction of the blockage. If it is still blocked after the movement, increase the notch width by 0.10 mm, but not exceeding 0.80 mm. When any channel is covered by the hydrophobic guard ring section, correct the corresponding opening center angle in the same direction. Re-prepare three pieces using the corrected screen and restore release only when all six channels are connected.

[0071] The liquid application quality of the three patterns is converted from the difference in weighing before and after the screen and the actual coverage area. When the coefficient of variation of the liquid application quality per unit area of ​​three consecutive cut pieces of hydrophilic micro dot array, transition ring and hydrophobic protective ring is not greater than 5%, the current screen speed and scraping parameters are retained. When the coefficient of variation of any pattern exceeds the limit, the corresponding screen is cleaned, the weighing sensor is recalibrated and recalculated with three new cut pieces. Cut pieces exceeding the limit are not written into the projection overlap inspection queue of S4.

[0072] The pattern application system uniformly transforms the hydrophilic micro-dot contours, transition ring boundaries, hydrophobic section boundaries, and water vapor channel paths into the cut piece coordinate system, generating a planar pattern record containing the cut piece number, origin coordinates, boundaries of each graphic, duty cycle, equivalent diameter distribution, channel connectivity status, and application batch number. This record is then used as the planar reference for S4 projection overlap verification.

[0073] In this specific embodiment, S3 includes:

[0074] Before applying the product batch solution, a calibration sheet with a thickness of 2.0±0.1 mm was taken from the same batch of fiber absorbent layer of S1. The hydrophilic and hydrophobic finishing dispersions were quantitatively applied to the skin-contact surface and the outer surface, respectively. The application amount per unit area was set to 20, 30, 40 and 50 g / m², the pressure difference was set to 5, 10, 15 and 20 kPa, and the pressure difference holding time was set to 2, 5, 8 and 12 seconds. Three parallel calibration sheets were prepared for each parameter combination and frozen for shaping within 60 seconds after application.

[0075] The frozen calibration sheet was sliced ​​along its thickness direction, and the characteristic signals of hydrophilic side chains and fluorine-free alkylsiloxane side chains were collected in 20-micrometer increments. 30% of the baseline characteristic signal of the corresponding uniformly cured image was used as the threshold for determining the penetration front. The first pair of adjacent sampling points on both sides of the threshold were searched from the corresponding liquid application surface into the layer. It was required that three consecutive sampling points below the threshold after crossing the threshold were used as noise immunity confirmation. The same linear interpolation formula defined in the S5 feedback section was then used to determine the penetration front. If the signals of two adjacent points were equal, no effective cross-threshold adjacent points were formed, or the noise immunity condition of three consecutive points was not met, the calibration sheet was marked as invalid and retested. The median of the interpolation front positions of three parallel calibration sheets was taken and written into the calibration dataset. If the range of the three front positions of any combination was greater than 0.15 mm, the group was discarded and the calibration was repeated.

[0076] Trilinear interpolation was performed on the calibration datasets of hydrophilic and hydrophobic dispersions respectively. A first calibration relationship and a second calibration relationship were established with the unit area application rate, pressure difference, and pressure difference holding time as joint query keys and the front position and parallel test dispersion as value fields. The calibration file recorded the raw material batch number, substrate thickness, measurement direction, parameter grid, signal threshold, effective time and version number. A new version of the calibration relationship was established when the substrate thickness changed by more than 5%, the dispersion solid content changed by more than 0.5 percentage points, or the raw material batch number was changed.

[0077] One record in the first calibration relationship maps the unit area application rate of the hydrophilic finishing dispersion of 30 g / m², pressure difference of 10 kPa, and holding time of 5 seconds to a leading edge position of 0.60 mm and a parallel test range of 0.06 mm. One record in the second calibration relationship maps the unit area application rate of the hydrophobic finishing dispersion of 40 g / m², pressure difference of 12 kPa, and holding time of 5 seconds to a leading edge position of 1.40 mm from the skin-contacting surface and a parallel test range of 0.08 mm. Each record simultaneously saves temperature, humidity, substrate batch number, and dispersion batch number to prevent the mixing of mappings under different conditions.

[0078] The product design uses the skin-contact surface as the origin of the thickness coordinate system, sets the first penetration front target range to 25% to 35% of the thickness, and the second penetration front target range to 65% to 75% of the thickness. The midpoints of these two ranges are used as the target positions for the first and second penetration fronts, respectively. Calculate the normalized frontier position. Indicates the first The normalized position of the penetration front relative to the skin-contact surface is a dimensionless number ranging from 0 to 1. The leading edge index is a dimensionless positive integer and Corresponding to the first penetration front, Corresponding to the second infiltration front, Indicates the first The distance from the infiltration front to the skin-contact surface, in millimeters, is obtained from the cross-sectional characteristic signal and is limited to between 0 and the measured thickness of the substrate. This indicates the measured thickness of the current fiber moisture-absorbing layer, in millimeters, obtained by taking the average value after measuring five points with a thickness gauge;

[0079] The liquid application controller uses the two target positions to look up the corresponding calibration relationship in reverse. It forms a candidate set of parameter combinations in which the positions of the leading edges both fall within the target interval and the normalized interval between the two leading edges is not less than 0.30. It deletes any combination in which any parameter exceeds the calibration grid. Then, it arranges the parallel test dispersion values ​​from smallest to largest. When the dispersion values ​​are the same, it selects the combination with the smallest liquid application amount per unit area. When the candidate set is empty, it keeps the double-sided liquid application valve closed and re-establishes the calibration relationship. In this specific implementation, 30 g / m², 10 kPa and 5 sec are selected for hydrophilic finishing dispersions, and 40 g / m², 12 kPa and 5 sec are selected for hydrophobic finishing dispersions.

[0080] The applicable target area is defined as a 35% to 65% thickness range that can accommodate two overlapping thicknesses, as set according to the fiber absorbent layer thickness ratio in the product design. The qualified predicate is that the applicable target area is completely contained by the closed interval between the two front edges. Equal boundaries are counted as inclusion, and the normalized interval between the two front edges is required to be not less than 0.30. In this specific embodiment, the thickness of the applicable target area is 0.30 times the measured thickness, which is sufficient to accommodate two overlaps of not less than 0.025 times the measured thickness and the transition area between them. Immediate cross-sectional sampling after liquid application must simultaneously meet the conditions that the coordinates of the first front edge are less than the coordinates of the second front edge and the above-mentioned inclusion predicate. If the front edge order is reversed, any boundary of the target area is outside the front edge interval, or the normalized interval is less than 0.30, the current cut piece is isolated, and the transition finishing dispersion application valve is kept closed as a safety state. After adjusting the unit area liquid application amount, pressure difference, or pressure difference holding time of the hydrophilic or hydrophobic finishing dispersion, the interval position of the two front edges is re-measured.

[0081] When the front sampling inspection meets the target range, three thickness labels are generated for the first penetration area, the second penetration area, and the blank fiber area between them. Each label saves the start and end coordinates, measurement uncertainty, witness sheet number, and front signal diagram. When the combined measurement uncertainty of the two front positions exceeds 0.10 mm, the sampling result is marked as uncertain and the cross-sectional sample is taken again. The uncertain front coordinates are not input as the interval position of S4.

[0082] The first penetration region formed by applying a hydrophilic finishing dispersion to the skin-contact surface and the second penetration region formed by applying a hydrophobic finishing dispersion to the outer surface were partially pre-baked. The initial temperature of the pre-baking oven was set to 80 degrees Celsius, and every 15 seconds, a set of two paired witness pieces cut from adjacent positions of the same continuous witness strip were taken, running synchronously with the product. The first piece was immediately frozen after being taken out and used to obtain the initial cross-sectional signal before the pressure difference was maintained. The second piece was held for 30 seconds under the same pressure difference as when the leading edge was formed and then immediately frozen and used to obtain the cross-sectional signal after the maintenance. At the same time, the characteristic signals of hydroxyl or blocked isocyanate were measured at the leading edge of the second piece. The center-to-center distance between the two paired witness pieces was no more than 2 mm and they were numbered sequentially along the machine direction. If any piece failed to prepare a sample, the entire set was discarded and a new set of paired witness pieces was obtained. The same witness piece that had already been sliced ​​was not measured again.

[0083] by Calculate the frontal displacement ratio. Indicates the first The ratio of the displacement of the penetration front to the substrate thickness during a 30-second differential pressure hold test is a dimensionless number with an upper limit of 0.05. Indicates the first The distance from the penetration front to the skin surface after a 30-second pressure differential hold, measured in millimeters, is obtained from the cross-sectional signal of the second piece in the paired witness film and is limited to 0 to the currently measured thickness. between, Indicates the first The distance from the infiltration front to the skin surface before the pressure differential is maintained, in millimeters, is obtained from the initial cross-sectional signal of the first of the paired witness films and is limited to 0 to the current measured thickness. between, The meaning, units, and sources are consistent with the definitions in step S above. The meaning of the index is consistent with the definition in step S above; any front distance exceeding 0 to If the thickness difference between the closed interval or two paired witness pieces exceeds 0.05 mm, the results of this set of sections are marked as invalid and resampled, and are not included in the calculation of the leading edge displacement ratio.

[0084] by Calculate the percentage of terminal groups retained in the reaction. Indicates the first The ratio of the characteristic signal of the reaction end group after pre-drying to the signal before pre-drying at the leading edge is a dimensionless number with a lower limit of 0.20. Indicates the first The peak areas of the characteristic signals of the reaction end groups after pre-baking at the leading edge and correction to the same baseline are dimensionless relative peak areas determined by infrared spectroscopy. Indicates the first The peak areas of the reaction end-group characteristic signals obtained before pre-baking at the leading edge using the same method are dimensionless relative peak areas and are greater than zero. The meaning of the index is consistent with the definition in the aforementioned step S;

[0085] The incomplete pre-drying is terminated only when the displacement ratio of both fronts is not greater than 0.05 and the reaction end-group retention ratio is not less than 0.20. If the displacement ratio exceeds the limit, the pre-drying is extended by 15 seconds and then retested. If the reaction end-group retention ratio is lower than the lower limit, the cut piece is isolated and the pre-drying is not extended. The first penetration area, the second penetration area, the positions of the two fronts, the penetration parameters and the pre-drying end time that have passed the test are written into the thickness direction record for S4 to determine the applicable range of the transition finishing dispersion.

[0086] In this specific embodiment, S4 includes:

[0087] The transition application controller reads the thickness direction record of S3. For every 50 pieces of cut material, one witness sheet is configured with the same speed and temperature. The witness sheet is frozen immediately after incomplete pre-baking and sliced ​​along the thickness direction. The hydrophilic side chain characteristic signal and the non-fluorinated alkyl siloxane side chain characteristic signal are collected with a step size of 20 micrometers. The first penetration front and the second penetration front are determined according to the front threshold of S3. The coordinates of the two fronts, the start and end positions of the interval, the thickness and the witness sheet number are written into the functional group mapping record.

[0088] The product design sets 35% to 65% of the fiber absorbent layer thickness as the applicable target range. The transition application controller uses the same unique qualified predicate as S3. First, it verifies that the thickness coordinate of the first penetration front is less than the thickness coordinate of the second penetration front. Then, it verifies that the closed range of 35% to 65% is completely contained by the closed range between the two fronts and the normalized interval of the fronts is not less than 0.30. Equal boundaries are considered as inclusion. The target range must accommodate at least two overlaps, each not less than 0.025 times the measured thickness. The total thickness ratio of the two overlaps is subsequently set at 0.05 to 0.30. If the front order is reversed, the boundary of any target range is outside the front interval, or the normalized interval is less than 0.30, the transition finishing dispersion valve is closed. The unit area liquid application rate, pressure difference, or pressure difference holding time of the hydrophilic or hydrophobic finishing dispersion is adjusted according to the calibration relationship, and the sample is re-prepared and measured.

[0089] When the leading edge sequence and the interval position are both qualified, the liquid application amount per unit area and the applied pressure difference are selected from the transition application calibration record based on the measured thickness of the interval. The calibration record is established with paired witness sheets of the same batch of substrate and transition finishing dispersion, and includes the interval thickness, liquid application amount, pressure difference, overlapping thickness on both sides, paired witness sheet number, two-dimensional composition discrimination boundary and batch version fields. In this specific embodiment, 35 g / m² and 8 kPa are selected when the interval thickness is 0.60 mm. If the query key exceeds the calibration range, no extrapolation is performed and the system returns to S3 to reselect parameters.

[0090] For each transition application calibration combination and each batch of 50 consecutive products, one baseline witness sheet and one result witness sheet are obtained from adjacent positions of the same continuous witness material. Both sheets are identical in shape and material, using the same origin, edge positioning marks, and a 1 mm orthogonal sampling grid. Both are processed at the same speed and temperature from S1 to S3. The baseline witness sheet is immediately frozen before entering the transition application station, and the result witness sheet is immediately frozen after the transition application is completed. Both sheets are destructively segmented along the same numbered grid lines, and micro-sections in the thickness direction are prepared from the corresponding nodes. Only when paired nodes... Only when the point plane positioning residual is no greater than 0.10 mm, the average thickness difference between the two pieces at five points is no greater than 0.05 mm, and the thickness coordinates are all normalized and matched from the skin-contact surface to the outer surface, are the hydrophilic side chain characteristic signals and the non-fluorinated alkyl siloxane side chain characteristic signals of the two pieces collected at a step size of 20 micrometers under the same instrument, characteristic band, and baseline correction parameters. The corresponding baseline witness sheet signal is then subtracted point by point from the result witness sheet signal. If any difference is negative, the pairing condition is not qualified, or the corresponding node is missing, no transitional discrimination result is generated, and the entire set of paired witness sheets is discarded and reconfigured.

[0091] Three parallel homogeneous curing pairs of dispersions (hydrophilic, transitional, and hydrophobic) were prepared using the same curing weight gain as the product. The side chain signals of the two types were converted to relative amounts of substance using their respective linear calibration curves, following the same method as with paired witness films. Provided the sum of the relative amounts of substance was greater than zero, the ratio of the relative amount of the hydrophilic side chain to the sum of the relative amounts of the two types of side chains was used as the two-dimensional composition coordinate. This ratio should be between 0.47 and 0.53 for all three parallel transitional pair dispersions, and between 0.72 and 0.78 for all three parallel hydrophilic pair dispersions. All hydrophobic pairs should be within the range of 0.17 to 0.23; the closed interval of 0.35 to 0.65 is set as the transition composition discrimination zone, and at the same time, the two types of side chain signals after pair subtraction should not be less than 20% of the corresponding reference signal of the transition pair; only sampling points that simultaneously meet the signal strength condition and the transition composition discrimination zone are marked as transition valid points. If any measured interval of a pair of photos exceeds the above corresponding range, or if the three types of intervals overlap after taking into account the measurement uncertainty, or if the linear calibration fails, the batch of two-dimensional composition discrimination is marked as invalid and the transition liquid application valve is kept closed.

[0092] A limited-depth microneedle ring-shaped liquid application head is inserted into the skin-contacting surface and the outer surface of the fiber absorbent layer, respectively. The closed needle tubes of the two sets of microneedles pass through the corresponding surface-side penetration areas without exiting liquid along the way. The liquid outlet of the needle tip on the skin-contacting surface terminates 0.05 mm from the first penetration front towards the second penetration front, and the liquid outlet of the needle tip on the outer surface terminates 0.05 mm from the second penetration front towards the first penetration front. The transition and dispersion are released synchronously at low pressure only from the blank fiber area between the two fronts. The controller does not use the wet internal cross-section signal, which cannot be directly obtained during operation, as the valve closing input. Instead, it reads the flow rate of the metering pumps on both sides and the valve opening time according to the aforementioned batch transition application calibration record. The cumulative liquid application volume reaching the target value of the calibration record is used as the independent valve closing condition. The first front two When all sampling points in the paired cross-sectional windows (0.05 mm on each side and 0.05 mm on each side of the second front edge) are effective transition points, the flow rate and opening time of this group can be written into the valid calibration range. Each batch of witness sheets is then offline verified according to the same pairing rules, so that the transition dispersion and the part of the first penetration area near the first front edge form a first thickness overlap, and the part of the second penetration area near the second front edge form a second thickness overlap. If an effective transition point appears on any surface side before the target window during the verification, it is determined that the microneedle side leak is detected. Immediately close both valves, remove the applied pressure difference, exit and lock the microneedle liquid application head, keep the equipment in a safe state that prohibits liquid application again and isolate the corresponding batch group until the paired witness sheet is replaced and the side leak check is passed before the lock is released.

[0093] by Calculate the ratio of the total thickness of the two overlapping thicknesses. This represents the ratio of the total thickness of the two overlapping layers to the measured thickness of the fiber absorbent layer. It is a dimensionless number with a release range of 0.05 to 0.30. This indicates the thickness of the intersection between the continuous interval of the effective transition point formed by the result witness film relative to the baseline witness film and the first penetration region determined by the absolute signal of the S3 hydrophilic side chain of the baseline witness film, expressed in millimeters. This indicates the intersection thickness between the continuous interval of the effective transition point and the second penetration region determined by the absolute signal of the S3 fluoroalkylsiloxane side chain on the baseline witness film, expressed in millimeters and measured using the same method. This indicates the measured thickness of the current fiber moisture-absorbing layer, in millimeters, and is obtained by averaging the thickness measurements from five points.

[0094] Before merging the two overlapping regions, the sampling points are determined point by point along the first overlapping region from its starting point to the second overlapping region in 20-micrometer increments, according to the aforementioned pairing subtraction, signal strength, and two-dimensional composition rules. The thickness-direction sampling points are arranged in ascending order of index from the skin-contact surface to the outer surface. Only when each valid sampling point is a transition valid point and all transition valid points constitute only one adjacent indexed continuous interval are the two overlapping regions and the continuous transition interval between them merged into a continuous finite overlapping region. Sampling points that directly cross blank areas, low-signal segments, or whose composition proportions are outside the transition composition discrimination region are prohibited from being used by coordinate intervals. If any sampling point does not meet the requirements... When the transition effective point condition or the transition effective point forms two or more non-adjacent index intervals, the passage is closed and the subsequent baking inlet is kept closed. The liquid application volume or pressure difference on the corresponding side is increased by one calibration level according to the shorter distance from the position of the invalid point to the liquid outlet on both sides, and the sample is re-prepared. The continuous area that passes the continuity judgment should have only one start point and one end point along the thickness direction. The distance from the start point to the skin-contact surface and the distance from the end point to the outer surface should not be less than 10% of the thickness of the fiber moisture-absorbing layer, so that the continuous limited overlapping area does not extend to the skin-contact surface and the outer surface. If any boundary distance is not qualified, the cut piece is isolated and the transition liquid application volume or pressure difference is reduced according to the direction of the leading edge deviation.

[0095] For every 50 product cut pieces, a set of full-size baseline witness pieces and result witness pieces, made of the same material and operating at the same speed and temperature as the product, are configured. The paired witness piece numbers are bound to the 50 products as an inspection batch according to the consecutive product cut piece numbers. The product cut pieces themselves are not destructively sliced. Micro-sections are prepared only on the paired witness pieces according to the aforementioned grid nodes with the same number and thickness coordinates. The three types of regions are reconstructed using independent and fixed signal paths: the first penetration region is determined solely by the absolute signal of the hydrophilic side chains of the baseline witness piece without pairing subtraction, according to the S3 first front threshold; the second penetration region is determined solely by the absolute signal of the non-fluorinated alkylsiloxane side chains of the baseline witness piece without pairing subtraction, according to the S3 second front threshold; and the continuous finite overlap region is determined solely by the differential signal obtained by subtracting the corresponding baseline witness piece from the result witness piece, according to the aforementioned signal strength, two-dimensional composition, and adjacent index continuity rules. The differential signal must not be used to generate the first or second penetration region labels, and the baseline absolute signal must not replace the differential signal. The signal generates transition valid points; the valid nodes of the three types of regions are respectively transformed to the cut piece coordinate system of S2, and the nearest neighbor region label is used to reconstruct adjacent valid nodes of the same type. Missing positions that are more than 1.5 mm away from the nearest valid node of the same type are not interpolated and are marked as invalid. When the invalid area in any pattern region exceeds 5% of the pattern area, the projection overlap ratio is not calculated and the paired witness pieces are reconfigured for the same batch. When projecting along the thickness direction, the first thickness projection set is generated with the first penetration area of ​​the baseline witness piece, the second thickness projection set is generated with the continuous finite overlap area of ​​the differential signal, and the third thickness projection set is generated with the second penetration area of ​​the baseline witness piece. The three types of two-dimensional thickness region projection pixel sets are formed according to the 20-micron planar pixel grid. When the paired witness piece is invalid, the resampling fails, or any projection index is unqualified, all 50 product cut pieces bound to it are isolated and cannot enter S5. Only when all the indexes of the paired witness piece are qualified are the S5 release mark written to the batch of products.

[0096] The planar pattern record of S2 is rigidly registered with the above-mentioned thickness region projection record according to the origin and edge positioning marks of the cut piece. When the positioning mark residual is no greater than 0.10 mm, the planar regions of the hydrophilic micro-dot array, transition ring, and hydrophobic protective ring are respectively intersected with the thickness projection regions of the first penetration region, the continuous finite overlap region, and the second penetration region. Calculate the projection overlap ratio. Indicates the first The projection overlap ratio between the planar pattern and the corresponding thickness region is a dimensionless number between 0 and 1. The pattern type index is a dimensionless positive integer and , and These correspond to the hydrophilic micro-dot array, transition ring, and hydrophobic protective ring, respectively. This function represents the conversion of plane area from registered image pixels, with the output unit being square millimeters. Indicates the first The pixel set of the planar pattern is a dimensionless coordinate set and is obtained from the planar pattern of S2. Indicates the relationship with the first The set of projected pixels for the thickness region corresponding to the pattern is a dimensionless coordinate set obtained from the aforementioned planar sampling grid and projection reconstruction results; it is not generated when the registration residual exceeds the limit. And reposition the data collection;

[0097] In this specific embodiment, the lower limit for the projection overlap ratio of the three types of patterns is set to 0.60. This is used to confirm that the three types of planar patterns at least partially overlap with the first penetration area, the continuous limited overlap area, and the second penetration area. When any projection overlap ratio is lower than the lower limit, the application position of the corresponding pattern screen is corrected according to the registered planar offset, without increasing the coverage area of ​​the dispersion to close the water vapor channel.

[0098] The cut pieces that pass the tests of frontal order, applicable target area, total overlap thickness ratio, boundary interval and projection overlap ratio are recorded as continuous limited overlap area records. The records save two penetration fronts, two thickness overlaps, continuous limited overlap areas, three types of pattern projections and channel status, and transmit the records to the segmented pre-baking, overall baking and curing feedback processes of S5.

[0099] In this specific embodiment, S5 includes:

[0100] The cross-process calibration database manages the activation parameter records of S1, the first and second calibration relationships of S3, the transitional application calibration records of S4, and the control threshold records of this S step by substrate batch number, dispersion batch number, thickness level, and effective time. Among them, the S1 activation parameter record is uniquely associated with the activated test piece of the same batch of substrate; the first and second calibration relationships of S3 are uniquely associated with the corresponding front-end calibration piece; the S4 transitional application calibration record is uniquely associated with the baseline witness piece and the result witness piece of the same batch, and is also associated with the three types of uniform curing pairs: hydrophilic, transitional, and hydrophobic; the control threshold records of this S step are uniquely associated with the three types of uniform curing pairs; and the overall baking witness piece is separately associated with the common pre-baking record, crosslinking conversion rate record, and moisture permeation release record. The database saves the source test piece number or witness piece number for each record and prohibits cross-substitution with different types of sources. When any raw material batch number changes, thickness level changes by more than 5%, the testing instrument is recalibrated, or the feedback results exceed the warning line for two consecutive batches, a new version is generated without overwriting the original version.

[0101] A calibration joint record includes the first substrate batch number of the day, thickness 2.0 mm, first hydrophilic dispersion batch number of the day, first transition dispersion batch number of the day, first hydrophobic dispersion batch number of the day, front-end judgment ratio 30%, coexistence judgment ratio 20%, liquid application rate per unit area, differential pressure, pre-drying time, baking temperature, baking time, migration limit, wash resistance limit, version number, and effective time. The finishing controller only reads this record when the joint key is completely matched. When there is no matching record for the joint key, the process status is marked as pending calibration and the previous batch parameters are stopped from being used.

[0102] The release results for each cross-sectional spectrum, planar image, moisture permeability and migration index are formed by three parallel samples. For continuous data, the original value is first recorded in the same unit. Then, the measured value that deviates from the median by more than three times the median absolute deviation is marked as an abnormal measurement and the original sample is retested. If it is still abnormal after retesting, the original sample is marked as invalid and resampled. The result of only two parallel values ​​after deleting abnormal data is not used as the release basis. The original data, operator and timestamp are saved for each retest, resampling and invalidation mark.

[0103] The curing controller reads the continuous limited overlap zone record of S4 and uses a common pre-baking program for the entire cut sheet before overall baking. First, the whole witness sheet of the same batch is pre-baked at 80±2 degrees Celsius for 50 seconds, 60 seconds and 70 seconds respectively. The remaining moisture mass ratio and reaction end group retention ratio are measured in the first penetration area, the continuous limited overlap area and the second penetration area respectively. The shortest candidate time with the remaining moisture mass ratio of the three areas all between 0.25 and 0.35 and the reaction end group retention ratio of the three areas not less than 0.20 is selected as the common residence time. In this specific embodiment, the common pre-baking program of 80±2 degrees Celsius and 60 seconds is selected. When the whole cut sheet passes through the three isothermal circulating air zones in sequence, the cumulative residence time of the three zones is controlled to 60 seconds, instead of assigning the three thickness areas of the same cut sheet to different temperature zones. If any candidate time cannot simultaneously meet the endpoint of the three areas, the overall baking inlet is kept closed and a new common pre-baking program is established for the raw material batch.

[0104] Three witness tablets were randomly selected from each batch for segmented pre-drying. The peak areas of the characteristic signals of the reaction end groups before and after pre-drying were measured in three corresponding regions. The retention results of the three regions were calculated according to the reaction end group retention ratio defined in S3. Only when the retention ratio of all three regions is not less than 0.20, the whole batch is allowed to proceed to baking. If the retention ratio of any region is less than 0.20, the batch is marked as over-pre-dried and isolated. The batch will not be accepted by reducing the subsequent baking intensity.

[0105] The cross-linking reaction window was determined by differential scanning calorimetry and infrared spectroscopy temperature rise tests of the common skeleton of the same batch. The temperature range in which the end group characteristic signal began to stabilize and decrease and the main chain did not show thermal decomposition characteristics was recorded as the effective window. In this specific embodiment, the overall baking was carried out at 150±2 degrees Celsius for 3 minutes within this window. The baking oven adopted a symmetrical circulating air volume for the skin-contact surface and the outer surface, so that the common skeleton of the three finishing dispersions cross-linked each other and reacted with the hydroxyl groups on the fiber surface in a continuous limited overlap area, forming a co-cured network spanning the three finishing regions.

[0106] by Calculate the crosslinking conversion rate of the continuous finite overlap region. This indicates the proportion of reaction end groups consumed by the crosslinking reaction to the reaction end groups before baking, and is a dimensionless number from 0 to 1. In this specific embodiment, the curing release value is 0.85. This represents the baseline-corrected peak area of ​​the characteristic reaction end-group signals within a continuous, finitely overlapping region after overall baking. It is a dimensionless relative peak area determined by infrared spectroscopy. It represents the peak area of ​​the characteristic signal of the reaction end group measured by the same method before overall baking. It is a dimensionless relative peak area and is greater than zero.

[0107] Within 30 seconds after the joint pre-drying, paired samples before baking were obtained from the same witness sheet, and their residual moisture mass ratio was recorded. A blank sample of the same area and residual moisture mass ratio before baking was also taken. The cup openings were sealed with impermeable aluminum foil, and the samples were simultaneously weighed in the same environment (38±1°C, 90±2% relative humidity outside the cup). The mass change per unit area of ​​the blank sample was used to correct for the mass change caused by water loss, moisture absorption, and state evolution of the unbaked finishing layer. For the permeable sample, the cup was kept at low humidity by anhydrous calcium chloride. The permeable cup weighing method was used to determine the permeability under the condition of equal pressure difference on both sides of the sample. Weighing was performed every 2 hours. When the relative deviation of the mass change rate per unit area after blank correction was no greater than 5% for three consecutive weighing intervals, the flux was considered stable, and the 24-hour permeability was calculated based on the stable interval. Baked samples were measured according to the same area, temperature and humidity, pressure difference, and stable flux criteria. Calculate the moisture permeability retention ratio. This represents the ratio of moisture permeability per unit area after baking to that before baking (after blank correction), and is a dimensionless number from 0 to 1. The preset retention ratio in this specific embodiment is 0.80. This represents the moisture permeability per unit area after baking, expressed in grams per square meter per 24 hours. It is obtained by averaging three parallel samples using the moisture permeation cup weighing method described above. The moisture permeability per unit area before baking, after deducting the change in mass of the closed blank sample in the same state and reaching a stable flux, is expressed in grams per square meter per 24 hours. It is obtained by averaging three parallel samples and is greater than zero. If any sample before baking fails to reach a stable flux within 24 hours or the result after blank correction is not greater than zero, the moisture permeability baseline is marked as invalid and a new sample is taken. It is not included in the moisture permeability retention ratio calculation. The batch of cured cut sheets is only released when the crosslinking conversion rate is not less than 0.85 and the moisture permeability retention ratio is within the closed interval of 0.80 to 1.

[0108] The cured cut pieces enter a countercurrent continuous washing line at 40±2 degrees Celsius. The washing line is equipped with 16 parallel single-piece channels that are isolated from each other and metered separately. The single-piece water flow rate of each channel is set to 0.5 liters / minute, and the total flow rate of the equipment when the 16 channels are running simultaneously is 8 liters / minute. Each channel switches to an independent fresh water tank every 5 minutes, and the extract at the end of the channel is collected at a sampling interval of 10 minutes. The total organic carbon and non-volatile matter content are measured simultaneously at each sampling point. The preset migration release limit for total organic carbon is set to 10 mg / L, and the preset migration release limit for non-volatile matter content is set to 20 mg / L. The two limits are consistent with the dimensions of the corresponding migration index and are determined by the migration limit of the skin-penetrating material and the limit of quantitation of the detection method of this batch.

[0109] The extraction controller stores the time series of two migration indicators for each individual channel, setting the upper limit of water extraction time to 120 minutes and the upper limit of cumulative extraction water consumption per unit to 60 liters. The cumulative extraction water consumption per unit is obtained by integrating the measured flow rate of 0.5 liters / minute of that channel with the extraction time. When three consecutive sampling points can be determined for the first time within 30 minutes, the cumulative water consumption is 15 liters, which does not reach the 60-liter upper limit. At each sampling moment, it is first determined whether the total organic carbon and non-volatile matter content has not exceeded the respective preset migration release limits for three consecutive sampling points, thus satisfying the requirements. If the condition is met and no upper limit has been reached, water extraction ends and tension setting is allowed; if three consecutive points are not qualified and any upper limit is reached first, the washing of the cut piece is immediately stopped, marked as migration abnormal, isolated and unset, and the process is transferred to parameter adjustment and verification sample flow; if three consecutive points are qualified and the upper limit occurs at the same sampling time, the upper limit trigger takes priority and is still treated as a migration abnormality; if any indicator does not reach the release limit and has not reached the upper limit, water washing continues and extraction cannot be ended based on only one indicator, and the total extraction time, measured flow rate of the channel and cumulative water consumption per piece are continuously recorded;

[0110] Cut pieces released after water extraction are first dehydrated using a centrifugal dehydrator to a moisture content of 60% to 80% relative to their oven-dry weight. Then, a bidirectional low-tension setting machine clamps the edges of the cut pieces along their warp and weft baselines. Tension setting parameters are pre-selected from candidate combinations of warp and weft tensions of 0.6, 0.8, and 1.0 N / cm, temperatures of 90, 100, and 110 degrees Celsius, and dwell times of 60, 90, and 120 seconds, based on the same batch of untreated substrate and the same batch of cured test pieces. Pieces not simultaneously achieving a warp and weft dimensional retention rate of 98% to 102% after setting, or a measured thickness not between 1.90 and 2.1, are eliminated. Combinations with a diameter of 0 mm, a pattern origin offset greater than 0.5 mm relative to the cutting piece positioning hole, or a moisture permeability retention ratio not within the 0.80 to 1 closed range; sort the remaining combinations lexicographically by temperature from low to high, dwell time from short to long, the sum of the absolute values ​​of the deviations of the warp and weft dimensional retention rates from 100% from small to large, the absolute value of the deviation of the measured thickness from 2.00 mm from small to large, the moisture permeability retention ratio from large to small, and the linear tension from low to high. Select the unique combination at the top of the sorted list and write it into the tension setting parameter record for this batch of substrate. If any level of comparison is equal, continue to use the next level to eliminate the difference. Repeat if all fields are equal. Measurement records are merged into the same combination. When the candidate set is empty, the shaping station is kept closed and a new candidate combination is established. In this specific implementation, the warp and weft tensions are 0.8±0.1 N / cm, 100±2 degrees Celsius, and 90 seconds, according to the sorting method. Then, the clamping tension is maintained and cooled with circulating air to no higher than 40 degrees Celsius. The shaping is then balanced for 30 minutes at 20±2 degrees Celsius and 65%±5% relative humidity as the shaping endpoint. The shaping controller records the feed moisture content, measured warp and weft tensions, measured temperatures in each temperature zone, dwell time, final cooling temperature, balancing time, and warp and weft tensions before and after shaping using the cut piece number as the key. If the dimensions, measured thickness, and pattern origin coordinates exceed the limits, the machine should be stopped immediately and the cut pieces from the most recent qualified record isolated. If any of the dimensions, thickness, or pattern origin offset is unqualified, the feedback release mark should be canceled. Only one re-sizing and complete retesting is allowed within the same batch of candidate combinations. If the retest is still unqualified or the query exceeds the candidate boundary, the shaping abnormality should be marked, isolated, and the process should be transferred to parameter adjustment and at least 3 verification samples. Only cut pieces with complete tension shaping parameter record fields and qualified dimensions, thickness, and pattern origin verification can enter the subsequent cross-section and plane feedback.

[0111] Cross-sectional feedback was performed on the shaped pieces to prepare uniformly cured contrast images of hydrophilic, transitional and hydrophobic finishing dispersions. The reference feature signals of the corresponding side chains were obtained on the hydrophilic and hydrophobic contrast images. 30% of the reference feature signals were set as the first frontal threshold and the second frontal threshold, respectively. 20% of the reference feature signals were set as the hydrophilic coexistence threshold and the hydrophobic coexistence threshold, respectively. Each ratio, contrast image batch number, feature band and baseline correction parameters were written into the control threshold record.

[0112] Two types of side chain characteristic signal curves were collected at 20-micrometer intervals along the thickness direction of the gradient-finding moisture-absorbing layer. Starting from the skin-contact surface, the first pair of adjacent sampling points whose hydrophilic side chain characteristic signals were located on both sides of the first leading edge judgment threshold were identified. Similarly, starting from the outer surface, the first pair of adjacent sampling points whose non-fluorinated alkylsiloxane side chain characteristic signals were located on both sides of the second leading edge judgment threshold were identified. For each first pair of sampling points... Perform linear interpolation. This represents the distance from the infiltration front to the skin surface obtained through interpolation, in millimeters, and is limited to between 0 and the measured thickness. This indicates the first sampling point closest to the search starting point in the first pair of sampling points. Each sampling point is located in millimeters, originating from the same cross-sectional sampling coordinates and limited to the range between 0 and the measured thickness. This represents the index of the next sampling point in the current valid sampling sequence. It is a dimensionless positive integer ranging from 1 to the total number of sampling points minus 1. The threshold for determining the leading edge of the current characteristic signal is a dimensionless relative peak area, recorded from the reference threshold. Indicates the first The characteristic signal of each sampling point is a dimensionless relative peak area obtained from the cross-sectional spectrum and corresponding baseline correction. Indicates the relationship with the first The location of the next sampling point adjacent to each sampling point, in millimeters, comes from the same cross-sectional sampling coordinates and is limited to between 0 and the measured thickness. The characteristic signal representing the next sampling point is a dimensionless relative peak area, originating from the same cross-sectional spectrum and using the same... The same baseline correction; only when and Interpolation is performed when the two points are unequal and form a valid cross-threshold adjacent point. If no valid cross-threshold adjacent points are formed, interpolation is not performed. The cross-sectional result is marked as invalid. The sample is resampled or re-sampled at a 20-micrometer interval. After obtaining valid adjacent points, the result is recalculated and written into the feedback record.

[0113] The connected sampling point segment located between two penetration fronts with hydrophilic side chain characteristic signals not less than the hydrophilic coexistence threshold and non-fluorinated alkyl siloxane side chain characteristic signals not less than the hydrophobic coexistence threshold is determined as the coexistence interval. When there are multiple coexistence intervals, they are sorted from largest to smallest continuous thickness value and the first one is selected as the continuous finite overlap area. When the continuous thicknesses of two or more coexistence intervals are parallel, their coordinates from the starting position of the skin surface are sorted from smallest to largest and the interval with the smallest coordinate value, i.e. the interval closest to the skin surface, is selected. When there are no coexistence intervals, an invalid cross section mark is generated and the generation of adjustment amount is stopped.

[0114] Functional group distribution map and wettability distribution map of the skin-adhesive surface are collected. The pixel classification threshold is determined based on the median of the pixel feature vectors and the intra-class dispersion of the three uniform curing pairs. Hydrophilic micro-dot array, transition ring, hydrophobic protective ring and water vapor channel not continuously covered are identified. The duty cycle of hydrophilic micro-dots and the connectivity status of water vapor channels are recalculated according to the duty cycle algorithm of S2 and the eight-neighbor connectivity rule. The projection overlap ratio of the three types of planar patterns with the first penetration area, the continuous finite overlap area and the second penetration area are obtained according to the projection overlap calculation rule of S4.

[0115] The feedback controller compares the two leading edge positions with the leading edge target range of S3, the position and thickness of the continuous finite overlap area with the applicable target range and the total overlap thickness ratio of S4, the micro-point duty cycle with the target range of 5% to 35%, the water vapor channel with the connectivity conditions, and the three projected overlap ratios with their respective target ranges of not less than 0.60. This allows for the comparison of each measured result with the corresponding target, generating a feedback comparison record with the measured value, target upper and lower limits, deviation sign, and release status. Parameter adjustment only occurs when S3 or S4 is in the same state. Within the batch calibration grid, perform a reverse query and change one parameter according to the smallest adjacent level: if the first leading edge coordinate is too large, prioritize reducing the application rate per unit area of ​​the hydrophilic dispersion by one level; if it is too small, increase it by one level. If the second leading edge coordinate is too large, prioritize increasing the application rate per unit area of ​​the hydrophobic dispersion by one level; if it is too small, decrease it by one level. If the application rate reaches the calibration boundary but is still not corrected, adjust the corresponding differential pressure by one level and the differential pressure holding time by one level in the same direction. If the midpoint of the overlapping area is biased towards the outer surface, prioritize reducing the transition application rate on the skin-contact side by one level or increasing the transition application rate on the outer surface side. Increase the application volume by one level, and adjust in the opposite direction if it leans towards the skin surface; for each adjustment of the overlapping midpoint, only use the smallest adjacent level verified in the same batch of S4 transition application calibration records that can move the midpoint in the target direction. If the calibration record lacks the required response direction, the measured response directions of adjacent levels are opposite, or the query exceeds the calibration boundary, stop the adjustment and re-establish the transition application calibration relationship; only increase the transition application volume on both sides by one level when the overlap thickness is insufficient, and decrease it by one level when the thickness exceeds the limit; when multiple deviations exist simultaneously, adjust according to the order of the leading edge, the position of the leading edge, the overlapping midpoint, etc. The overlap thickness, micro-dot duty cycle, water vapor channel, and projection overlap ratio are processed sequentially, with only one item modified at a time and retested with no less than 3 verification samples. When the query exceeds the calibration boundary, the adjustment is stopped and a new calibration relationship is established. The planar pattern offset is moved by a 20-micron pixel step in the opposite direction of the registration offset vector. When the duty cycle is too low or too high, the screen opening is increased or decreased by one screen opening position respectively. When the water vapor channel is not connected, the corresponding guard ring opening is enlarged by one angle position first. All adjustments are only applied to the subsequent fiber moisture-absorbing layer and do not cover the original measurement records of the current batch.

[0116] Pre-set continuous water extraction records serve only as a release basis for tension-based setting and do not replace post-set migration verification. For each completed settling test batch, three verification samples from the same batch are randomly selected and independently water extracted at a flow rate of 0.5 L / min on a small countercurrent migration verification line at 40±2°C. The terminal migration test solution of each verification sample is collected every 10 minutes, and the total organic carbon and non-volatile matter content are simultaneously determined, still using the corresponding release limits of 10 mg / L and 20 mg / L. The maximum time limit for post-set migration verification is 120 minutes per sample. The cumulative water consumption limit is 60 liters. Only when both indicators of the three verification samples are no greater than the release limit at their respective three consecutive sampling points and have not yet reached either upper limit will the type-fixed migration verification of the test batch be marked as passed and enter the washability verification. If any verification sample first reaches the time or water consumption limit, the upper limit and the three consecutive points of pass occur at the same time, or any indicator still exceeds the limit, the extraction of the corresponding verification sample will be stopped immediately, the type-fixed migration verification will be marked as abnormal and the batch will be isolated, and the parameter adjustment and retesting process of no less than three verification samples in this S step will be connected.

[0117] The washability verification used a fixed washing program numbered TW-20-v1 to complete 20 washing cycles. In each cycle, the verification sample was placed in a drum washing solution containing 5 g / L of neutral phosphate-free detergent at a liquor ratio of 1:20 and a temperature of 40±2 degrees Celsius. The sample was mechanically tumbled at 50 rpm for 30 minutes, then rinsed twice with deionized water at the same liquor ratio for 5 minutes each time. The sample was then drum dried at 60±2 degrees Celsius. The drying endpoint for a single cycle was defined as a mass change of no more than 0.5% between two adjacent 10-minute weighing intervals. The washing program number, equipment number, measured water temperature, liquor ratio, detergent batch number, rotation speed, time of each stage, and drying endpoint were all recorded in the washability verification record. If any field was missing or the program version was incompatible, the verification was stopped and marked as pending completion. After completing 20 effective cycles, the characteristic signal distribution curves of the two hydrophilic side chains before and after washing, as well as the characteristic signal distribution curves of the two non-fluorinated alkylsiloxane side chains, were sampled to the same normalized thickness coordinates. The average value of each curve was subtracted, and the normalized correlation coefficient of each side chain characteristic signal distribution curve was obtained by dividing the dot product of the deviation vectors of the curves before and after washing by the product of the L2 norms of the two vectors. Both correlation coefficients were limited to -1 to 1, and the lower limit of release was set to 0.90. Before calculation, the L2 norms of the mean-free deviation vectors before and after washing were required to be greater than zero. If any L2 norm was equal to zero, no correlation coefficient was generated, the measurement of the curve was marked as invalid, and the original sample was retested according to the abnormal measurement rules of this step S. If the retest result was still zero, the sample was resampled.

[0118] The dimensionless position deviation ratio is calculated by dividing the absolute difference between the midpoint of the continuous finite overlap area after washing and the midpoint before washing by the measured thickness of the fiber moisture-absorbing layer, and the dimensionless thickness ratio is calculated by dividing the thickness of the continuous finite overlap area after washing by the thickness before washing. In this specific embodiment, the upper limit of the position deviation ratio is set to 0.05, and the release range of the thickness ratio is set to 0.85 to 1.15. The four results of the two normalized correlation coefficients, the position deviation ratio, and the thickness ratio are compared with their respective washability release limits. If any of the four results does not meet the corresponding washability release limit, the washability verification result is marked as abnormal.

[0119] When the migration verification results are abnormal, adjust the amount of crosslinking agent according to the hydroxyl equivalent of the three dispersions and the isocyanate equivalent after the crosslinking agent is unsealed, so that the reaction end group equivalent ratio of the three dispersions is within the preset co-curing equivalent ratio range of 0.95 to 1.05. According to the type of index that exceeds the migration release limit, increase at least one of the following: water temperature, water flow rate per unit time, water exchange frequency, extraction time or extraction water volume, but do not exceed the upper limit of temperature and the upper limit of flow rate in the equipment calibration record.

[0120] When the wash resistance verification results are abnormal, if the position deviation ratio is unqualified, only adjust the amount of transition liquid on both sides according to the offset direction of the midpoint of the aforementioned overlapping area, and do not replace position correction by simply increasing the overlapping thickness; if the thickness ratio is lower than 0.85, increase the amount of transition liquid on both sides by one calibration level within the total overlapping thickness ratio range of 0.05 to 0.30, and decrease the amount of transition liquid on both sides by one level if the thickness ratio is higher than 1.15; if the normalized correlation coefficient of the distribution curves of the two side chain characteristic signals is unqualified, first increase the overall baking time by 15 seconds within the effective window of the crosslinking reaction and the upper limit of the equipment, and if it is still unqualified, increase the baking temperature by 2 degrees Celsius. Only one item is adjusted each time, and it is retested with no less than 3 verification samples. After each adjustment, it is necessary to re-verify that the crosslinking conversion rate is not less than 0.85 and the moisture retention ratio is in the closed interval of 0.80 to 1.

[0121] At least three verification samples were prepared using the adjusted parameters. The pattern application, double-sided penetration, transition overlap, segmented pre-baking, overall baking, water extraction, cross-sectional and planar feedback, migration verification, and wash resistance verification were performed. The adjusted parameters were written into the new version of the process parameter record and the subsequent processing was resumed only when all verification samples were not marked as abnormal in migration verification and wash resistance verification. If any verification sample was abnormal, the production was marked as suspended and the effective parameter version was not updated. In this way, a polymer hydrophilic and hydrophobic gradient finishing method for the moisture-absorbing layer of a nursing bra was completed and a gradient-finished moisture-absorbing layer that meets the conditions for migration release and wash resistance release was obtained.

[0122] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

[0123] This invention uses the same crosslinkable polymer backbone to support different side chain compositions, so that the hydrophilic, transitional and hydrophobic dispersions have compatible crosslinking end groups while maintaining the wettability order; the bidirectional penetration front, incomplete pre-baking and mid-section transition jointly define the position of the continuous limited overlap region, and the overall baking thereby forms a co-cured network that spans the three polymers and connects the fiber surface.

[0124] This invention also utilizes cross-sectional and planar mapping to verify the leading edge, overlapping region, micro-lattice, annular pattern, water vapor channel, and projection registration. For migration or wash resistance anomalies, the crosslinking, water extraction, overlapping, and baking parameters are reverted to ensure that subsequent finishing is restored after meeting the safety constraints of migration and wash resistance verification.

Claims

1. A method for finishing the moisture-absorbing layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient, characterized in that, include: S1. Provides a fiber moisture-absorbing layer and a hydrophilic finishing dispersion, a transition finishing dispersion and a hydrophobic finishing dispersion with the same crosslinkable polymer backbone, wherein the water contact angle of the three cured layers increases sequentially. S2. A hydrophilic finishing dispersion is used to form a hydrophilic microarray in the nipple-corresponding area of ​​the skin-contacting surface of the fiber moisture-absorbing layer, and a transition ring and a hydrophobic protective ring are formed in sequence around it using a transition finishing dispersion and a hydrophobic finishing dispersion. S3. A hydrophilic finishing dispersion is applied from the skin-adhering surface to form a first penetration region extending to the first penetration front, and a hydrophobic finishing dispersion is applied from the opposite outer surface to form a second penetration region extending to the second penetration front, so that the two penetration fronts are spaced apart, and the two penetration fronts are partially pre-baked to stop macroscopic flow and retain the reaction end groups. S4. Apply a transitional dispersion between the two penetration fronts, so that it overlaps with the first penetration region and the second penetration region in thickness, forming a continuous limited overlap region that does not extend to the skin-contact surface and the outer surface, and make the projections of the hydrophilic micro-lattice, the transition ring and the hydrophobic protective ring along the thickness direction at least partially overlap with the first penetration region, the continuous limited overlap region and the second penetration region. S5. Overall baking, so that the polymers of the three finishing dispersions form a co-curing network between each other and with the fiber surface, followed by water extraction until the migratable residue index is not greater than the corresponding preset migration release limit, to obtain a gradient finishing moisture-absorbing layer.

2. The method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient according to claim 1, characterized in that, S1 includes: Before using the fiber absorbent layer as the finishing substrate, the fiber absorbent layer is surface-cleaned, and based on the wetting tension test results of the fiber surface after cleaning, one of the following methods is performed: plasma activation, corona activation, and aqueous coupling agent activation, so that the activated wetting tension reaches the preset dispersion spreading threshold. The crosslinkable polymer backbone is one of aliphatic polyurethane and polyurethane-acrylic copolymer. The three finishing dispersions have the same type of crosslinking end groups that can react with each other and react with the fiber surface. The molar proportion of hydrophilic side chains in the hydrophilic finishing dispersion is greater than the molar proportion of non-fluorinated alkylsiloxane side chains. The transition finishing dispersion contains both hydrophilic and non-fluorinated alkylsiloxane side chains. The molar proportion of non-fluorinated alkylsiloxane side chains in the hydrophobic finishing dispersion is greater than the molar proportion of hydrophilic side chains.

3. The method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient according to claim 1, characterized in that, S2 include: The duty cycle of the hydrophilic micro-array is set to 5% to 35%, the equivalent diameter of a single hydrophilic micro-dot is set to 0.1 mm to 2 mm, and water vapor channels that are not continuously covered by the hydrophilic dispersion are maintained between adjacent hydrophilic micro-dots; a transition ring is formed starting from the outer boundary of the hydrophilic micro-array, and a hydrophobic protective ring is formed starting from the outer boundary of the transition ring, and the hydrophobic protective ring is composed of hydrophobic sections spaced along the circumference, so that the hydrophobic protective ring does not block the water vapor channels.

4. The method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient according to claim 1, characterized in that, S3 includes: on a calibration sheet having the same material and thickness as the fiber absorbent layer, changing the unit area application rate, pressure difference, and pressure difference holding time for the hydrophilic finishing dispersion, establishing a first calibration relationship between the unit area application rate, pressure difference, and pressure difference holding time of the hydrophilic finishing dispersion and the position of the first penetration front; changing the unit area application rate, pressure difference, and pressure difference holding time for the hydrophobic finishing dispersion, establishing a second calibration relationship between the unit area application rate, pressure difference, and pressure difference holding time of the hydrophobic finishing dispersion and the position of the second penetration front; determining the midpoint of each of the first and second front target intervals set according to the fiber absorbent layer thickness ratio in the product design as the target positions of the first and second penetration fronts, respectively; querying the first calibration relationship based on the target position of the first penetration front; querying the second calibration relationship based on the target position of the second penetration front; determining the unit area application rate, pressure difference, and pressure difference holding time of the two finishing dispersions respectively, so that an interval is maintained between the two penetration fronts for receiving the transition finishing dispersion.

5. The method for finishing the polymer hydrophilic-hydrophobic gradient of the moisture-absorbing layer of a nursing bra according to claim 4, characterized in that, The endpoint of the incomplete pre-drying is determined by the displacement of the front edge and the amount of reactive end groups retained: after maintaining the same pressure difference as when the corresponding penetration front edge is formed for 30 seconds, the displacement of the corresponding penetration front edge does not exceed 5% of the thickness of the fiber moisture-absorbing layer, and the reactive end group characteristic signal at the corresponding penetration front edge after pre-drying is not less than 20% of the corresponding characteristic signal before pre-drying, the incomplete pre-drying ends.

6. The method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient according to claim 4, characterized in that, S4 includes: Functional group mapping was performed using witness sheets or cross-sectional samples obtained from the fiber hygroscopic layer after the formation of two penetration fronts to determine the spacing of the two penetration fronts. The product design sets a region that can accommodate two overlapping thicknesses according to the fiber moisture-absorbing layer thickness ratio, and is designated as the applicable target region. When the order of the two penetration fronts is reversed from S3 or the interval position does not fall within the applicable target region, the application of the transition finishing dispersion is stopped, and the unit area liquid application rate, pressure difference, or pressure difference holding time corresponding to the hydrophilic or hydrophobic finishing dispersion is adjusted, and the interval position of the two penetration fronts is re-measured. When the interval position falls within the applicable target region, the unit area liquid application rate and applied pressure difference of the transition finishing dispersion are controlled according to the interval position, so that the transition finishing dispersion forms thickness overlaps with the part of the first penetration area near the first penetration front and the part of the second penetration area near the second penetration front, respectively. The total thickness of the two thickness overlaps is 5% to 30% of the fiber moisture-absorbing layer thickness, and the continuous limited overlap area is kept at a distance from both the skin-contact surface and the outer surface.

7. The method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient according to claim 6, characterized in that, Before the overall baking in step S5, segmented pre-baking is performed. The segmented pre-baking includes setting the corresponding pre-baking temperature and pre-baking time according to the water evaporation rate of each of the hydrophilic, transitional, and hydrophobic dispersions, so that the three dispersions retain the reaction end groups before overall baking. The temperature and time of overall baking are determined according to the cross-linking reaction window of the common skeleton, so that the cross-linking conversion rate of the three polymers in the continuous limited overlap region reaches the preset curing release value, and the ratio of the moisture permeability per unit area after baking to that before baking is within the closed interval of the preset retention ratio to 1.

8. The method for finishing the absorbent layer of a nursing bra with a polymer hydrophilic-hydrophobic gradient according to claim 7, characterized in that, The water extraction employs a continuous water washing method, collecting extracts at set sampling intervals, and selecting at least one of the following as the migratable residue index: total organic carbon, non-volatile matter content, and target residue content. Based on the migration limit of the skin-penetrating material corresponding to each selected migration index, preset migration release limits with the same dimensions as the migration index are set. When the detection values ​​of all selected migration indices at three consecutive sampling points are not greater than their respective preset migration release limits, the water extraction ends and the gradient finishing moisture-absorbing layer is shaped.

9. The method for finishing the moisture-absorbing layer of a nursing bra with a hydrophilic-hydrophobic gradient according to claim 8, characterized in that, Following S5, the process includes a cross-sectional and planar feedback step: uniformly cured images of the hydrophilic, transitionally cured, and hydrophobic cured dispersions are prepared respectively; reference feature signals of corresponding side chains are obtained on the uniformly cured images of the hydrophilic and hydrophobic cured dispersions; a first and second leading edge determination thresholds are determined based on the product of each reference feature signal and a first preset ratio; and hydrophilic coexistence thresholds and hydrophobic coexistence thresholds are determined based on the product of each reference feature signal and a second preset ratio; distribution curves of hydrophilic side chain feature signals and fluorine-free alkylsiloxane side chain feature signals are obtained along the thickness direction of the gradient-treated moisture-absorbing layer, and applied to the skin surface. The process begins by identifying the first pair of adjacent sampling points whose hydrophilic side chain feature signals are located on either side of the first infiltration front threshold. Linear interpolation is then performed between these adjacent sampling points to determine the first infiltration front. Similarly, starting from the outer surface, the process continues by identifying the first pair of adjacent sampling points whose non-fluorinated alkyl siloxane side chain feature signals are located on either side of the second infiltration front threshold. Linear interpolation is then performed between these adjacent sampling points to determine the second infiltration front. The connected region between the two infiltration fronts, where the hydrophilic side chain feature signal is not less than the hydrophilic coexistence threshold and the non-fluorinated alkyl siloxane side chain feature signal is not less than the hydrophobic coexistence threshold, is defined as the coexistence region. When multiple coexistence regions exist, the coexistence region with the highest continuous thickness value is selected. As a continuous finite overlap region, when the continuous thickness values ​​of two or more coexisting regions are tied for first place, the coexisting region with the first value of the coordinate value at the starting position of the skin-attached surface is selected as the continuous finite overlap region. When there is no coexisting region, an invalid cross-section marker is generated and the generation of adjustment amounts is stopped. The functional group distribution map or wettability distribution map of the skin-attached surface is obtained. Based on the pixel classification threshold determined by three uniform curing methods for the photographs, the hydrophilic microarray, transition ring, hydrophobic protective ring, and water vapor channels that are not continuously covered are identified. The duty cycle of the hydrophilic microarray, the connectivity status of the water vapor channels, and the projection of the hydrophilic microarray, transition ring, and hydrophobic protective ring with the first penetration region, the continuous finite overlap region, and the second penetration region are calculated. The overlapping ratio is determined by comparing the measured results with the corresponding targets. The target ranges are: the leading edge target range and the overlapping area target range set according to the fiber absorbent layer thickness ratio in the product design, as well as the duty cycle target range, channel connectivity condition, and projection overlap ratio target range set according to the planar pattern. Based on the positional deviation in the thickness direction, at least one of the following is adjusted: the unit area liquid application rate, pressure difference, pressure difference holding time, and pre-drying time of the corresponding finishing dispersion. Based on the deviation of the planar pattern or projection overlap ratio, at least one of the following is adjusted: the duty cycle, droplet size, pattern application position, transition ring width, and hydrophobic guard ring width of the hydrophilic microarray.

10. The method for finishing the moisture-absorbing layer of a nursing bra with a hydrophilic-hydrophobic gradient according to claim 9, characterized in that, Migration and wash resistance verifications were performed on the shaped gradient finishing moisture-absorbing layer: an upper limit for extraction time and an upper limit for extraction water volume were set. If the detection value of the selected migration index is still greater than its corresponding preset migration release limit when either upper limit is reached, the migration verification result is marked as abnormal. Complete at least 20 washing cycles according to the preset washing program, calculate the normalized correlation coefficient of the hydrophilic side chain characteristic signal distribution curve before and after washing, the normalized correlation coefficient of the non-fluorinated alkylsiloxane side chain characteristic signal distribution curve, the ratio of the position deviation of the continuous finite overlap area to the thickness of the fiber moisture-absorbing layer, and the ratio of the thickness of the continuous finite overlap area after washing to that before washing. Compare the four results with their respective wash resistance release limits. If any one of them does not meet the corresponding wash resistance release limit, the wash resistance verification result is marked as abnormal. When the migration verification result is abnormal, adjust the corresponding crosslinking agent dosage according to the equivalent of the reactive end groups contained in each of the three finishing dispersions, and ensure that the equivalent ratio of the reactive end groups of the three finishing dispersions is within the preset co-curing equivalent ratio range. At the same time, adjust at least one of the following: water temperature, water flow rate per unit time, water exchange frequency, extraction time, and extraction water volume. When the wash resistance verification result is abnormal, adjust at least one of the following: thickness of the continuous finite overlap zone, overall baking temperature, and overall baking time. Prepare a verification sample using the adjusted parameters and repeat the migration verification and wash resistance verification. The fact that neither verification result is marked as abnormal is used as a safety constraint for resuming subsequent finishing processes.

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