A multi-layer fabric and fabric edge seaming apparatus

Abstract

The application provides a kind of multilayer fabric and fabric edge welding device, and the device includes ultrasonic roller and scraper assembly.The outer circumferential surface of the roller is provided with a convex array, which is composed of mirror-symmetrical annular matrix groups, each group contains staggered sub-ring matrix, and the narrow edge incomplete welding defect is eliminated by axially overlapping molten zone;The groove and the convex of the scraper are precisely embedded, and the specific angle of the scraper lip is realized to clean the convex array on the surface of the roller simultaneously.The design significantly reduces the glue residue, ensures the stability of continuous welding, and the obtained fabric edge has high welding strength and good air permeability.

Description

Technical Field

[0001] This application relates to the field of fabric processing technology, specifically to a multilayer fabric and a fabric edge sealing and welding device. Background Technology

[0002] Ultrasonic welding of fabrics is an advanced process that utilizes high-frequency mechanical vibration (typically 20~40kHz) to generate heat through friction at the molecular level in thermoplastic fiber materials, achieving efficient solid-state bonding through localized melting. Its core lies in the precise patterns on the welding head surface (such as a combination of U-shaped and dotted patterns) that focus the vibrational energy onto the fabric contact interface, raising the temperature to the material's melting point (e.g., 160~170℃ for polypropylene) within 0.1~0.5 seconds. The melt flows under pressure and penetrates the fiber pores, forming a dual-bonded structure of mechanical interlocking and molecular chain entanglement upon cooling. This technology is particularly suitable for lightweight nonwoven fabrics (hot air fabric / spunbond fabric with a basis weight of 15~20g / m²) such as disposable hygiene products (e.g., diapers with ultra-narrow side seals ≤5mm) and medical protective clothing. 2 The high-speed welding process, with a single-point welding speed of 0.5 seconds, high tear strength, and environmentally friendly characteristics without chemical adhesives, overcomes the heat damage of traditional hot pressing processes and the hard texture of sewing processes. At the same time, the optimized pattern ensures the welding strength and softness and breathability under narrow edge conditions.

[0003] The side seals of trouser-style disposable sanitary products are generally achieved using hot pressing or ultrasonic welding. If ultrasonic welding is used, the weld strength at the side seal position must be at least 8N to meet product quality standards. In existing technology, considering both functionality and aesthetics, the side seals of trouser-style disposable sanitary products often employ ultrasonic embossing welding. Common embossing patterns include U-shaped and herringbone patterns. Figure 1 As shown, patent CN118977422A discloses a multi-layer fabric edge-sealing welding structure, specifically an embossed pattern with a main body in the shape of a regular U or an inclined U, which meets the welding strength requirements of the side seal position of disposable sanitary products for trousers, combining functionality and aesthetics. While the U-shape can enhance the side seal strength, it also presents the problem of adhesive accumulation. Due to the irregularity of the U-shaped pattern, adhesive easily accumulates in the U-shaped area and is difficult to clean. Utility Model Content

[0004] The purpose of this application is to provide a multilayer fabric and a fabric edge sealing welding device to solve the above-mentioned problems existing in the prior art.

[0005] In a first aspect, a fabric edge sealing welding device is provided, including a roller, the outer peripheral surface of which is provided with a protrusion array, the protrusion array being used to weld fabric by melting thermoplastic material. The fabric edge sealing welding device also includes a scraper, the protrusion array including a plurality of protrusions extending circumferentially along the roller, the scraper including a scraping lip and a groove, the groove being positioned corresponding to the protrusions, the scraping lip being attached to the outer peripheral surface of the roller and at least embedded in the area between the protrusion arrays, the scraping lip being used to clean adhesive from the surface of the roller.

[0006] Furthermore, the protrusions form at least two annular matrices on the outer circumference of the roller, with the points on the axis of the roller as the centers and the radius of the annular matrices being the radius of the roller.

[0007] Furthermore, the protrusions form two sets of annular matrices on the outer circumferential surface of the roller, and the two sets of annular matrices are mirror-symmetrical.

[0008] Furthermore, each set of the annular matrix includes two annular linear arrays, and the protrusions in the two annular linear arrays are staggered. The staggered arrangement means that the projection of the gap between two adjacent protrusions in one annular matrix onto the protrusion in the other annular matrix along the axis of the roller falls into the protrusion.

[0009] Furthermore, each set of the ring matrix includes two ring linear arrays, with a gap between the two ring linear arrays.

[0010] Furthermore, the protrusion is strip-shaped. Further, the strip shape can be rectangular, or a "grain of rice" shape with rounded corners. Even further, the rectangular protrusion has a length of 2-5 mm and a width of 0.5-1.5 mm.

[0011] Furthermore, the protrusion is arranged perpendicular to the axis of the roller.

[0012] Furthermore, the roller achieves high-frequency mechanical vibration through ultrasound, causing the thermoplastic material molecules of the fabric to generate heat through friction, thus achieving solid-state welding.

[0013] Furthermore, the circumferential cross-section at the intersection of the scraper and the roller forms an angle of 60-80°.

[0014] In a second aspect, a multilayer fabric is provided, wherein the fabric edge sealing is performed using the fabric edge sealing welding device as described in the first aspect of the invention.

[0015] Beneficial effects: This device reduces adhesive accumulation during edge sealing welding of multi-layer nonwoven fabrics through the synergistic structure of the annular matrix of raised strips on the roller surface and the dedicated scraper assembly. The annular raised array employs a mirror-symmetrical arrangement and staggered sub-rings within the same group, ensuring axial overlap and coverage of the welding molten zone, eliminating the risk of incomplete penetration in narrow sealing areas. The scraper assembly, with its grooved structure and scraper lip design that fits into the raised array, simultaneously cleans the roller substrate surface and the gaps between the raised strips, reducing molten residue and ensuring process stability during long-term continuous operation. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of a U-shaped embossing pattern in the prior art; Figure 2 This is a schematic diagram of a fabric edge-sealing welding device provided in an embodiment of this application; Figure 3 for Figure 2 A magnified view of a portion of the image; Figure 4 This is a schematic diagram of the roller structure in an embodiment of this application; Figure 5 This is a schematic diagram of the scraper structure in an embodiment of this application; Figure 6 This is a schematic diagram of a U-shaped embossed pattern in an embodiment of this application.

[0018] Explanation of reference numerals in the attached diagram: 1-roller, 11-protrusion, 2-scraper, 21-scraper lip, 22-groove. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Unless otherwise defined, the technical or scientific terms used in this application should have the ordinary meaning understood by those skilled in the art to which this utility model pertains. The words "first," "second," and similar terms used in this application do not indicate any order, quantity, or importance, but are only used to distinguish different components. The words "comprising" or "including," etc., mean that the element or object preceding the word covers the element or object listed after the word and its equivalents, but do not exclude other elements or objects. The words "connected," "coupled," or "linked," etc., are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. "Up," "down," "left," "right," etc., are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0020] The preferred embodiments of this application are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit this application. Furthermore, the embodiments and features in the embodiments of this application can be combined with each other without conflict.

[0021] like Figure 2-6 As shown, the fabric edge sealing welding device provided in this embodiment includes a roller 1, a scraper 2, and a cooperating structure. It also includes a transducer, an amplitude transformer, and a rotary connector.

[0022] The roller 1 is made of alloy steel and has an array of rectangular protrusions 11 distributed on its outer circumference. This array consists of at least two sets of annular protrusion arrays, each set including several protrusions 11 extending circumferentially along the roller 1. For example, when used for welding the hot air fabric / spunbond composite layer of diapers, the protrusions 11 are strip-shaped, with a length of 5 mm and a height of 0.6 mm. The length direction of the strip structure can be perpendicular to the axis of the roller 1. The protrusions 11 can form two sets of annular matrices on the surface of a 120 mm diameter roller (each set of annular matrices contains two annular linear arrays, for a total of four annular linear arrays). The protrusions between the two annular linear arrays in the same set are staggered—the axial projection of the gap between the protrusions 11 on the inner annular linear array precisely falls into the center of the adjacent protrusions 11 in the outer annular linear array. This staggered design creates an overlapping fusion zone in the welding area, effectively avoiding incomplete penetration defects at the edge of the sealing strip.

[0023] In addition, roller 1 can apply 20kHz axial high-frequency vibration while rotating at high speed, and protrusion 11 presses the fabric contact surface to make the polypropylene fiber instantly heat up to 170°C, and the melt penetrates into the adjacent fiber layer to form a continuous weld line.

[0024] The scraper 2 can be composed of a scraping lip 21 and a groove 22 forming the core working part. The scraping lip 21 can be attached to the outer peripheral surface of the roller 1 at a 75° angle for surface cleaning. The depth of the groove 22 can be slightly greater than the height of the protrusion, for example, it can be 0.1 mm greater than the height of the protrusion. The position of the groove 22 is strictly aligned with the position of the annular linear array. When the roller 1 rotates past the scraper 2, the protrusion 11 is precisely embedded in the groove 22, and the gap between the two can be controlled within ±0.05 mm, so that the scraping lip 21 is in complete contact with the base of the roller 1, thoroughly removing the molten overflow, thereby cleaning the adhesive on the surface of the roller 1. For example, in the actual test of the baby diaper production line, a basis weight of 17 g / m³ is used. 2 Hot air cloth with 15g / m 2 When welding spunbond fabric composites, the scraper 2 produces less than 0.8mg of residue after running continuously for 8 hours. Compared with traditional flat scrapers, it reduces glue accumulation by 91% and reduces the frequency of weld strength attenuation caused by impurities.

[0025] The fabric sealing and welding device utilizes a dual-function array of protrusions: its annular matrix arrangement generates a composite welding trajectory. For example, during fabric sealing, two sets of mirror-symmetrical annular matrices act synchronously on the nonwoven fabric layers, forming two parallel weld lines axially. The melt generated by the strip protrusions forms a continuous sealing band. Simultaneously, an axial gap is maintained between the two sets of annular matrices as a heat dissipation channel, preventing heat accumulation that could cause the thin spunbond fabric to melt through. Furthermore, the mirror-symmetrical annular matrix design ensures balanced welding pressure on both sides, preventing interlayer misalignment when hot-air fabrics of different basis weights are bonded to spunbond fabrics.

[0026] The specific process for implementing fabric edge sealing welding using this fabric edge sealing welding device is as follows: The fabric layer to be welded (such as the four layers of material at the side seam of a diaper) is fed between roller 1 and the anvil. Roller 1 rotates at a linear speed of 30 m / min and is subjected to longitudinal ultrasonic vibration. The raised array compresses the material interface, generating frictional heat and forming a local molten pool within 0.25 seconds. Scraper 2 simultaneously cleans the surface of roller 1, and scraper lip 21 removes trace amounts of molten residue from the surface of the roller 1 substrate. After cooling under pressure for 0.15 seconds, the edge-sealing welded product is output.

[0027] Actual tests show that the welding strength is stable in the range of 9.1-9.9N (the standard requires ≥8N), and the weld line air permeability retention rate exceeds 83% of the original material, balancing sealing performance and comfort. See Table 1 for a comparison of the tensile strength tests.

[0028] Table 1

[0029] Based on the same inventive concept, this application also provides a multi-layer fabric, which is edge-sealed using the aforementioned fabric edge-sealing welding device. The embossed pattern of the edge-sealed fabric produced by this device is as follows: Figure 6 As shown, it includes multiple pressure points arranged in a linear array, the shape and position of which correspond to the protrusion 11 of the roller 1.

[0030] Although preferred embodiments have been described in this application, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the embodiments of this application.

[0031] Obviously, those skilled in the art can make various modifications and variations to the embodiments of this application without departing from the spirit and scope of the embodiments of this application. Therefore, if these modifications and variations to the embodiments of this application fall within the scope of the claims in this application and their equivalents, then this application also intends to include these modifications and variations.

Claims

1. A fabric edge-sealing welding device, comprising a roller (1), wherein the outer peripheral surface of the roller (1) is provided with a protrusion array, the protrusion array being used to weld the fabric by melting a thermoplastic material, characterized in that, It also includes a scraper (2), the protrusion array includes a plurality of protrusions (11), the protrusions (11) extend circumferentially along the roller (1), the scraper (2) includes a scraping lip (21) and a groove (22), the groove (22) is positioned corresponding to the position of the protrusions (11), the scraping lip (21) is attached to the outer peripheral surface of the roller (1) and is at least embedded in the area between the protrusion array, the scraping lip (21) is used to clean the adhesive on the surface of the roller (1).

2. The fabric edge sealing welding device according to claim 1, characterized in that: The protrusion (11) forms at least two annular matrices on the outer circumferential surface of the roller (1), with the point on the axis of the roller (1) as the center and the radius of the annular matrix being the radius of the roller (1).

3. The fabric edge sealing welding device according to claim 2, characterized in that: The protrusion (11) forms two sets of annular matrices on the outer circumferential surface of the roller (1), and the two sets of annular matrices are mirror-symmetrical.

4. The fabric edge sealing welding device according to claim 3, characterized in that: Each of the annular matrices includes two annular linear arrays, and the protrusions (11) in the two annular linear arrays are staggered. The staggered arrangement means that the projection of the gap between two adjacent protrusions (11) in one annular matrix onto the protrusion (11) in the other annular matrix along the axis of the roller (1).

5. The fabric edge sealing welding device according to claim 3, characterized in that: Each of the aforementioned annular matrices comprises two annular linear arrays, with a gap between the two annular linear arrays, the gap being 0.5mm-1.5mm.

6. The fabric edge sealing welding device according to claim 1, characterized in that: The protrusion (11) is strip-shaped.

7. The fabric edge sealing welding device according to claim 6, characterized in that: The protrusion (11) is arranged perpendicular to the axis of the roller (1).

8. The fabric edge sealing welding device according to claim 1, characterized in that: The roller (1) uses ultrasonic waves to achieve high-frequency mechanical vibration, causing the thermoplastic material molecules of the fabric to generate heat through friction and solid-state welding.

9. The fabric edge sealing welding device according to claim 1, characterized in that: The circumferential cross-section of the scraper (2) and the roller (1) at the intersection forms an angle of 60~80°.

10. A multilayer fabric, characterized in that, Welding and sealing are performed using the fabric edge sealing welding device as described in any one of claims 1-9.

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