apparatus and methods for impacting fluids against subtracts

专利摘要:
APPARATUS AND METHODS TO IMPACT FLUIDS AGAINST SUBSTRATESThe present invention relates to an apparatus and methods for impacting fluids, for example, heated fluids, against the substrate surface and then locally removing the impacted fluid. The apparatus may comprise at least a first and a second fluid distribution outlet which are in a divergent relationship with each other. The apparatus can comprise at least a first and a second fluid capture inlet which are positioned locally in relation to the first and second fluid distribution outlets, respectively. The apparatus and method can be used, for example, to impact fluids against two converging substrates and can be used to heat the surfaces of the substrates in order to facilitate the bonding by melting the substrates together.
公开号:BR112012015373A2
申请号:R112012015373-0
申请日:2010-12-20
公开日:2020-09-15
发明作者:Kristopher K. Biegler；A. Ferreiro Jorge；Gorman Michael R.；Panza Victor F.；Parodi Omar A.；Gabriela F. Serra；William C. Unruh
申请人:3M Innovative Properties Company；
IPC主号:

专利说明:

s * ”1/42“ APPARATUS AND METHODS FOR IMPACTING FLUIDS AGAINST SUBSTRATES ”Background Fluids, for example, heated fluids are impacted against a substrate for a variety of purposes.
For example, heated fluids can be impacted against a substrate for the purpose of annealing, drying a surface coating, promoting a chemical reaction or physical change, and the like.
Often, the impacted fluid is allowed to escape into the surrounding atmosphere, where it can be allowed to disperse or can be at least partially removed by a duct, cap, or the like. . 10 Summary This document describes an apparatus and methods for impacting. fluids, for example, heated fluids, against the substrate surface and then locally remove the impacted fluid.
The apparatus can comprise at least a first and a second fluid distribution outlet which are in a divergent relationship with each other.
The apparatus can comprise at least a first and a second fluid capture inlet which are positioned locally in relation to the first and second fluid distribution outlets, respectively.
The apparatus and method can be used, for example, to impact fluids against two converging substrates and can be used to heat the surfaces of the substrates in order to facilitate the bonding by melting the substrates together.
In one aspect, an apparatus is described for impacting fluid against at least a first surface of a first moving substrate and a first surface of a: second moving substrate and locally removing the impacted fluid, which comprises: at least one first outlet fluid distribution; at least one capture entry. 25 fluid which is locally positioned in relation to the first fluid distribution outlet; at least a second fluid delivery outlet; at least a second fluid capture inlet that is locally positioned in relation to the second fluid distribution outlet; and with at least one first fluid distribution outlet and at least one second fluid distribution outlet being in a relationship | 30 divergent.
In another aspect, a method of impacting the heated fluid against, and locally removing the impacted fluid, a first surface of a first moving substrate and a first surface of a second moving substrate is described, the method comprising: providing at least a first fluid distribution outlet and at least a first fluid capture inlet that is locally positioned relative to the first fluid distribution outlet; provide at least a second fluid distribution outlet and at least one mm MM MM MM “mM“ c225M5, 2/42 | second fluid capture input that is locally positioned in relation to the second fluid distribution outlet; passing the first moving substrate through the first fluid distribution outlet and impacting the heated fluid from the first outlet against the first main surface of the first moving substrate; passing the second moving substrate through the second fluid distribution outlet and impacting the heated fluid from the second outlet against the first main surface of the second moving substrate; and, locally capture at least 6% of the total volumetric flow of the impacted fluid through the fluid capture inlets and remove the locally captured fluid through the fluid removal channels that are. 10 fluidly connected to the fluid capture inlets; and the first and second moving substrates are convergent substrates.
. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a side view of an exemplary laminate comprising an exemplary fibrous mat that is surface-bonded to an exemplary substrate with a thick retaining bond.
Figure 2 is an illustrative description, in schematic side view in partial cross section, of a portion of a laminate comprising a fibrous mat with portions of fiber connected by surface to a substrate.
Figure 3 is an illustrative description, in lateral schematic view in partial cross section, of a portion of a laminate comprising a fibrous mat with a portion of fiber embedded in a substrate.
Figure 4 is an illustrative description, in schematic side view in section: partial cross-section of a laminate comprising a fibrous blanket with a portion of fiber fused to a substrate.
. 25 Figure 5 is a scanning electron micrograph taken at 130X magnification, of an example laminate that comprises a non-woven fibrous blanket bonded by surface to a substrate.
Figure 6 is a scanning electron micrograph taken at 180X magnification of an example laminate that comprises a fibrous non-woven blanket connected by surface to a substrate.
Figure 7 is a top view of two exemplifying substrates connected to an exemplary fibrous mat.
Figure 8 is a side view of an exemplifying apparatus and process that can be used to connect a first substrate to a second substrate.
Figure 9 is an expanded side view in partial section of a portion of the exemplary apparatus and process of Figure 8.
, 3/42 Figure 10a is a diagrammatic cross-sectional illustration of a portion of an exemplary apparatus and process that can be used to impact the heated fluid against a substrate and remove the impacted fluid locally.
Figures 10b and 10c describe additional ways in which the exemplary apparatus and process of figure 10a can be operated.
Figure 11 is a partial side view of an exemplifying apparatus and process that can be used to impact the heated fluid against two substrates and to locally remove the impacted fluid, and connect the two substrates together.
Figure 12 is a diagrammatic cross-sectional illustration of a portion of. 10 another exemplifying apparatus and process that can be used to impact the heated fluid against a substrate and remove the impacted fluid locally.
. Similar reference numbers in the various figures indicate similar elements. Some elements can be present in similar or identical multiples; in these cases, the elements may comprise the same reference number, with one or more of the elements designated by an apostrophe (") for convenience of description. Except where otherwise noted, all figures and drawings in this document are not to scale and are selected for the purpose of illustrating different modalities of the invention. In particular, the dimensions of the various components are shown for illustrative purposes only and no relationship between the dimensions of the various components should be inferred from the drawings, unless otherwise indicated. terms such as "top", "bottom", "top", bottom "," below "," above "," front "," rear "," out "," in "," above "and" in down ”, and“ first ”and“ second ”can be used in this description, it should be understood that these terms are used in their relative sense only, except where otherwise specified.
- 25 Detailed Description Shown in figure 1 is a side perspective view of an example laminate 150 comprising a fibrous mat 110 which is attached to substrate 120. The fibrous mat 110 is composed of fibers 111, and comprises a first main surface 112 and a second main surface opposite to 113. (Those skilled in the art will recognize that the surfaces 112 and 113 of the mat 110 may not be perfectly flat and / or continuous physical surfaces as they are collectively defined by the outermost portions of certain fibers. 111 of blanket 110). Laminate 150 further comprises a substrate 120, which comprises the first main surface 121 and a second oppositely facing main surface 122. The substrate 120 can optionally comprise protuberances 123 projecting from the main surface 122.
In the illustrated embodiment, the fibrous mat 110 is bonded by surface to the substrate 120 (specifically, the first main surface 112 of the fibrous mat 110 is bonded by
; 4/42 surface to the first main surface 121 of substrate 120). This means that the fibrous mat 110 is attached to the substrate 120 by means of some fibers 111 of the surface 112 of the mat 110 being bonded by surface - to the first main surface 121 of the substrate
120. As shown illustratively in Figure 2, the designation that fibers 111 are surface bonded to the first main surface 121 of the substrate 120 means that parts of the fiber surfaces 115 of fiber portions 114 of the fibers 111 are melted bonded to the first main surface 121 of substrate 120, such that it substantially preserves the original (pre-bonded) shape of the first main surface 121 of substrate 120, and substantially preserves at least some portions of the first '10 main surface 121 of substrate 120 in one condition exposed, in the area connected by surface. + The requirement that the surface bond substantially preserve the original shape of the first main surface 121 means that the fibers bonded by the surface can be distinguished from the fibers that are bonded to a substrate in a way that results in portions of fiber being embedded (for example, partially or completely encapsulated) on the substrate (as shown illustratively in figure 3) at least by means of partial penetration of the fibers into the substrate, deformation of the substrate, and the like. Quantitatively, the surface bonded fibers can be distinguished from the embedded fibers 116 at least by means of about 65% of the surface area of the surface bonded fiber being visible above the substrate surface in the bonded portion of the fiber (although an inspection of more than an angle may be needed to view the entire surface area of the fiber). Substantial preservation of the original (pre-bonded) format of substrate 120 can also be manifested by the absence of any gross changes in the physical shape of the first main surface 121 (eg. 25 crinkling, distortion, penetration of portions of substrate 120 in interstitial spaces of blanket 110, etc.).
The requirement that the surface bond substantially preserve at least some portions of the first main surface 121 in an exposed condition means that fibers bonded by surface can be distinguished from fibers that are bonded to a substrate in such a way that results in fibers being sufficiently melted, densified , compacted, mixed etc. to form a continuous bond. A continuous bond means that the fibers immediately adjacent to the first main surface 121 of the substrate 120 have mixed and / or densified sufficiently (for example, melted together to partially or completely lose their identity as individual fibers) to form a continuous layer. of material at the top, and in contact with, the first main surface 121. (Those skilled in the art will recognize the possibility of occasional spans, and the like, in a “continuous” layer, and will appreciate that, in this context, the term continuous can be mp Ei le./M ““ 7 ”ME + j 5/42 interpreted to mean that, in a bonded area, the continuous densified fiber layer is at the top, and in contact with, at least about 95 % of the area of the first main surface 121 of the substrate 120). Therefore, the fibers bound by surface can be distinguished from the fibers bound in a continuous bond, by the presence of several exposed areas where the first main surface 121 of substrate 120 is visible between the surface-bound fibers that constitute the first main surface 112 of the fibrous mat 110. Scanning electron micrographs (at 130X and 180X magnification, respectively) of exemplary non-woven fibrous blankets surface bonded to substrates are shown in Figures 5 and 6. In these micrographs, the previously described surface bond '10 of fiber portions to the substrate surface is readily apparent, with minimal deformation or damage to the bound fiber portions or substrate, and . with several exposed areas of the substrate surface being visible among the fibers connected by surface.
As defined herein, the term "surface bonded" means that a mat is meltedly bonded to a substrate primarily by the surface bonded fiber portions described above, and furthermore means that in the absence of such surface bonds the fibrous mat and the substrate would not remain linked together.
Those skilled in the art will recognize that the term "surface bonded" as used in this way does not cover situations where the primary bond between a fibosa blanket and a substrate occurs by some other melt bonding mechanism (for example, by embedding fibers in the substrate , and the like), with the portions of fiber bound by surface being found only occasionally within the bound area: or the areas of the blanket.
Therefore, those skilled in the art will appreciate that the surface bond as described in the present invention does not cover such a bond by + 25 fusãotal as is commonly obtained, for example, by ultrasound bonding, by compacting bonding (for example, as obtained by passing the substrates through a contact line heated in a relatively high pressure), by extrusion lamination and the like.
These processes are well known for resulting in large-scale deformation and / or physical changes in the fiber and / or substrate portions, in the formation of the bond.
Elements skilled in the art will further assess that fibrous blankets that are bonded to substrates that are still in a molten, semi-molten, soft state, etc., (such as extruded materials that have not yet been cooled, for example, in a solid condition), may not comprise a surface bond, since bonding to a substrate that is still at a high temperature and / or is still considerably deformable, can cause the fibers to become encrusted, can cause formation of a continuous connection, or both.
, 6/42 Those skilled in the art will further recognize that although the embedded fiber portions, the regions almost continuously connected on a small scale, and the like, may occasionally occur in a blanket that has been surface-bonded to a substrate as described in the present invention, these characteristics may represent only the sporadic occurrence of such characteristics in the bonding process.
As stated earlier, the term surface bonded means that although such encrusted fiber portions and / or fiber regions almost continuously connected may be present to a small extent, most of the connections between the fiber portions and the substrate are surface connections , so that the absence of such surface bonds,. 10 any unforeseen bonding by means of encrusted fibers and / or regions almost continuously bound would be so insignificant that the fibrous mat and the substrate would not remain bonded together.
Those skilled in the art will further recognize that although the surface bonding of the fiber portions to a substrate as described in the present invention may lead to individual bonds that are weaker than the bonds obtained by encrusting the fibers in the substrate or bonding them if the fibers are continuously to the substrate, the surface bond as described in the present invention can provide an acceptable bond between a fibrous mat and a substrate if carried out in a sufficiently large area or areas.
That is, the surface connection can advantageously be carried out in one area or large areas (here called "area connection"), as opposed to the small area connection (often referred to as point connection) that is usually obtained by ultrasound union, and the like.
This connection by area means that the large number of portions of fiber. surface bonded (which may be random and / or uniformly present in the bonded area) can collectively provide a bonding strength suitable for the laminate 150 to be. 25 handled and performed satisfactorily in various end uses.
In various embodiments, these areas connected by surface between the fibrous mat 110 and the substrate 120 may comprise an area of at least about 100 mm square, at least about 400 mm square, or at least 1000 mm square.
Therefore, the person skilled in the art will again be able to readily distinguish such a link by area from the site link or the dot link that are generally employed in other fusion link processes.
At least through the methods presented here, surface bonding can easily be carried out over a large proportion of the area of overlap or contact between a fibrous mat and a substrate.
Specifically, the fibrous mat 110 and substrate 120 may comprise an overlapping area (for example, in which a first surface 112 of mat 110, and a first surface 121 of substrate 120, face each other and / or are in contact with each other). Of this overlapping area, at least about 70%, at least about 80%, at least about
. 7/42 and 90%, or substantially all, may comprise an area or areas connected by surface.
Surface bonding as presented herein can provide advantages over other melt bonding methods. Specifically, within the bonded area, the surface bond can minimize any deformation of the substrate 120 and can minimize the number of fibers 111 that are embedded in the substrate 120 and / or are continuously bonded to the substrate 120. Therefore, laminate 150 can remain quite flexible even in the connected area. The surface connection as shown here can be made up to the point. 10 in which substrate 120 and fibrous mat 110 are not separable from each other, or without severely damaging one or both substrate 120 and fibrous mat 110.
. In some embodiments, fibers bonded by surface can in general, or substantially, retain their original (pre-bonded) shape. In these embodiments, the surface-bonded fibers retaining the shape can be distinguished from the fibers that are bonded to a substrate by means of a fiber portion being fused to the substrate, (the term fused means in the process of bonding the fiber portion if it has become substantially deformed in relation to its original pre-bonded structure and physical shape, for example, the fiber portion has become substantially flattened), as shown in an illustrative manner in Figure 4. Quantitatively, the surface bound fibers retaining the shape can be distinguished from fused fibers 117 by means of surface-bonded fibers that remain sufficiently circular in cross section because they exhibit an aspect ratio (ie a ratio between the largest cross-sectional dimension of the fiber and the smallest. cross-sectional dimension) in the bonded portion of the fiber not greater than about 2.5: 1 (as obtained by an average based on a series of fibers r representative). In many . In the embodiments, the fibers may comprise an aspect ratio of no more than about 2: 1, or no greater than about 1.5: 1. Those skilled in the art will realize that this method of identifying fibers connected by shape retaining surfaces may only be suitable for fibers of generally circular cross-sectional shapes as originally produced; if fibers of other shapes are used, it may be necessary to compare the shape in cross section of the fibers as originally produced with the shape after a bonding operation, in order to carry out the determination. Likewise, those skilled in the art will recognize that some deformation of the shape in cross section of some portion of some fibers connected by surface retaining the shape may occasionally occur due to the presence of other fibers in contact with the portions of the fiber while the fibers are at a high temperature (some of these occurrences are visible in Figure 6). The fibers connected by surface o ”the MM MD ME. 8/42. shape retainers that exhibit deformation for this reason should not be considered to be the same as fused fibers.
In the embodiment illustrated in Figure 1, the fibrous mat 110 is connected to the substrate 120 by means of a thickness retaining connection. This means that the fibrous mat 110 is fused to the substrate 120 in such a way that the fibrous mat 110 retains a significant amount of the thickness displayed by the fibrous mat 110 prior to the bonding process.
Thickness is a term of the technique in relation to fibrous blankets, and consists of a measurement of the degree of opening, lack of compaction, presence of interstitial spaces, etc., inside a fibrous blanket. As such, any common thickness measurement can be used. For reasons . 10 For convenience, in this document, the thickness of a fibrous mat will be represented by the ratio between the volume occupied by the mat (including fibers as well as the interstitial spaces of the mat that are not occupied by fibers) and the volume occupied by the fiber material. alone. Using this measurement, a thickness retaining connection as described in the present invention is defined as one in which the connected fibrous web 110 comprises a thickness that is at least 80% of the thickness displayed by the web before, or in the absence of, a process binding. If only a portion of the fibrous web 110 has substrate 120 attached to it, the retained thickness can be easily ascertained by comparing the web thickness in the area attached to that of the web in an unalloyed area. If the entire fibrous mat 110 has substrate 120 attached to it (or if the mat in a non-bonded area has also been subjected to compaction during the bonding process), it may be necessary to compare the thickness of the mat bound to that of a mat. sample from the same blanket before being turned on. In various embodiments, laminate 150 comprises a thickness-retaining connection such that the fibrous web 110 comprises at least 90%, at least 95%, or substantially all of its pre-bonded thickness. The elements skilled in the art will recognize that in some embodiments the laminate 150 may not comprise a surface bonded laminate as described in the present invention (for example, a significant number of fibers 111 comprising the first main surface 112 of fibrous web 110 may be embedded in the substrate 120 and / or continuously attached to substrate 120), however, in these cases, the fibrous mat 110 can be attached to substrate 120 in a thick retaining bond.
The thickness retainer connection as presented herein can provide advantages over other melt connection methods. Specifically, within the bonded area, the thickness-retaining bond can leave the fibers of the fibrous mat 110 that are not on the first main surface 112 of the mat 110 intact and / or not melt-bonded to the substrate 120. Therefore, the mat fibrous 110 can remain thick, resilient and / or flexible even in the bonded area (in these cases, the fibrous blanket 110 may be more
. 9/42 easily attached by male fastening elements, may have a more pleasant tactile sensation and / or appearance, etc.). In contrast, other bonding methods can disadvantageously crush or densify all or almost all fibers in the bonded area and / or can melt bond them to the substrate, with loss of desirable properties such as thickness and flexibility. Therefore, those skilled in the art will appreciate that the thickness-retaining bond as described in the present invention does not cover such a fusion bond as is commonly obtained, for example, by ultrasound bonding, by compacting bonding (for example, as obtained by passing the substrates through a contact line heated in a relatively high pressure), by extrusion lamination and similar, when such. 10 processes result in significant crushing and / or densification of the bonded mat.
Those skilled in the art will recognize that other bonding methods, for example, additional point bonding, can be used at certain locations on the laminate in addition to the surface bonding and / or thickness retaining bond described herein, for example, if desired. accentuate the connection as a whole.
Although the methods presented here (for example, heated fluid collision on the surfaces of two converging substrates; or, heated fluid collision on the surfaces of two converging substrates with local removal of the impacted heated fluid) may be particularly suitable for production of surface bonded laminates, bonded laminates with retained thickness, or both, the elements skilled in the art - it will be assessed, based on the descriptions contained herein, that other methods may also be suitable. Such methods can include any process by which heat can be imparted to the first surfaces of two substrates in such a way that the first surfaces of the two substrates can be fused together to obtain the structures described herein.
Substrate 120 can be any substrate to which it is desired to surface bond the fibrous mat 110. Substrate 120 can be produced from any suitable thermoplastic polymeric material (for example, a material that is melt bondable). Such materials may include, for example, polyolefins, polyesters, polyamides, and various other materials. Examples of suitable polyolefins include polyethylene, polypropylene, polybutylene, ethylene copolymers, propylene copolymers, butylene copolymers, and copolymers and blends of such materials. The substrate may comprise various additives and the like, as are well known in the art, as long as such additives do not unacceptably reduce the ability of the substrate to be fused. The substrate 120 can be multilayered, for example, a coextruded multilayered film, provided that the first main surface 121 is "capable of being bonded by melting to at least some of the fibers of the fibrous web 110.
In some embodiments, substrate 120 may comprise a preformed substrate, this means that substrate 120 is a pre-existing film previously produced
'10/42 whose physical properties in general have developed completely. This should be contrasted, for example, with a case where a substrate is produced (for example, extruded) and in general taken directly in the bonding process described here in a condition in which it is still generally molten, semi-molten, soft, or similar.
The substrate 120 can have any desired thickness. In various embodiments, the thickness of the substrate 120 (not including the height of the protrusions) can be less than about 400 microns, less than about 200 microns, less than about 100 microns, or less than about 50 microns. In some embodiments, substrate 120 does not comprise any adhesive (i.e., thermo-melt adhesive, pressure sensitive adhesive, and the like), for example, in the form of coatings on a main surface of the mat.
In some embodiments, substrate 120 can be continuous, that is, without any penetrating orifice through. In other embodiments, the substrate 120 may be —discontinuous which comprises, for example, penetrating through holes and the like. In some embodiments, substrate 120 may be composed of a dense non-porous material. In some embodiments, substrate 120 may be composed of dense porous material. In particular embodiments, substrate 120 may comprise a fibrous web, for example, a non-woven fibrous web.
In some embodiments, the first main surface 121 and the second opposite main surface 122 of substrate 120 may be free from protrusions. In other embodiments, the optional protrusions 123 can project from the second main surface 122 of the substrate 120, as shown in the example design of figure 1. (In this particular design, the protuberances 123 are on the opposite side of the substrate 120 from - which should be connected). The protrusions 123 can be of any desired type, shape or design, present and any desired density per area of the substrate 120, as desired for any suitable purpose. The protrusions 123 can be integral (i.e., of the same composition, and formed at the same time as a unit) to the substrate 120.
In various embodiments, protuberances 123 may comprise a maximum height (above surface 122) of at most about 3 mm, about 1.5 mm, about 0.8 mm, or about 0.4 mm. In additional embodiments, protrusions 123 may comprise a minimum height of at least about 0.05 mm, about 0.1 mm, or about 0.2 mm. In various embodiments, protrusions 123 may comprise an aspect ratio (the ratio of the height of the protrusion to the largest width of the protrusion) of at least about 2: 1, at least about 3: 1, or at least about 4: 1.
, 11/42 - In some embodiments, the protuberances 123 comprise fastening elements: male, for example, hooks, of the type that are capable of interconnecting with a fibrous material and that can serve as the hook component of a supposed hook and loop closure. Any male fastening elements can be used. In particular embodiments, fastening elements comprising a relatively large stem and head (which may, for example, have a generic mushroom shape, a flattened disc, and the like), of the general type described in US 6,558 patents, can be used. .602,
5,077,870, and 4,894,060. Suitable substrates with protrusions comprising male fasteners include, for example, those products available from 3M Company, St. Paul, MN, USA, under the trade name CS200 and CS 600. Other suitable substrates include, for example, those described in US patents 7,067,185 and 7,048,984. The connection as described in the present invention can be particularly advantageous in the connection by melting a fibrous mat 110 to a substrate 120 comprising protrusions 123 (in particular, male fasteners), because the connection may be able to be carried out without significant damage (for example, deformation, crushing, flattening, etc.) to the lumps in the attached area. Therefore, in some embodiments, the bonding processes as described in the present invention are performed in such a way that the substrate 120 of laminate 150 comprises protrusions 123 that have not been significantly damaged. The term “not significantly damaged” means that upon visual inspection (for example, through a microscope powerful enough to reveal details of individual protuberances), no more than one protuberance out of ten protuberances exhibits any damage such as deformation, crushing, melting, and similar, when compared to lumps that have not been subjected to the bonding process. In additional modalities, less than one lump in twenty exhibits damage. In an additional embodiment, substantially all of the lumps are undamaged. For the particular case in which the substrate protrusions are male fastening elements, the absence of significant damage to the protrusions can also be manifested in the retained detachment performance of the substrate. For example, when fitted to any suitable loop component and subjected to any of the detachment tests well known for quantitatively characterizing the performance of hook and loop closure system components, the substrate, after being subjected to the bonding processes described here , can retain at least about 80 percent of the peeling performance of the originally produced substrate. In several embodiments, the substrate's peeling performance can remain at least about 90%, —only about 95%, of the peeling performance of the originally produced substrate. Those skilled in the art will appreciate that many bonding processes significantly or even completely compress all protuberances in the bonding process.
. 12/42 RA obtain a bond and therefore will again assess the fundamental differences between bonding methods and bonded laminates presented here, and those presented in the art.
The fibrous mat 110 can be any suitable fibrous mat with sufficient mechanical strength to be handled as a self-supporting mat and subjected to the bonding processes described herein.
As such, it will be understood that laminate 150 as described in the present invention does not cover any article that does not comprise a pre-existing self-supporting fibrous mat that is laminated to a substrate (such non-covered articles may include, for example, fibers produced by - blow melt (meltblown) deposited on a talaguça, and the like). In some embodiments, the fibrous web 110 may comprise interwoven fibers such as those obtained by weaving, knitting, suturing and the like.
As such, the fibrous mat 110 may be composed of a suitable fabric or textile, provided that the materials comprising the fibers are suitable for the bond described in this document.
Therefore, although the blanket 110 may, occasionally for reasons of convenience of illustration, be called a non-woven fibrous blanket, it is understood that the blanket 110 can comprise any suitable fibrous material.
In some embodiments, the fibrous web 110 comprises a nonwoven fibrous web.
Any suitable self-supporting fibrous non-woven blanket 110 can be used, produced from any desired material, as long as the connection described in this document can be made.
The non-woven fibrous mat 110 can be, for example, a carded mat, a continuous spinning mat, a hydroentangled mat, an airlaid mat, or a mat produced by block extrusion with air passage. hot at high speed (meltblown) (that is, as long as the blanket has undergone sufficient processing to make it self-supporting). The non-woven fibrous mat 110 can be a multilayer material with, for example, at least one layer of a mat produced by block extrusion with high-speed hot air (meltblown) and at least one layer of a spinning mat. continuous, or any other suitable combination of non-woven blankets.
For example, the nonwoven fibrous web 110 may be a multilayer material of continuous spinning-bonded by continuous fusion-spinning, continuous spinning-continuous spinning, or continuous spinning-continuous spinning-continuous spinning.
Or, the blanket can be a composite net comprising a non-woven layer and a layer of dense film, as exemplified by blankets comprising non-woven fibers bound in loops that project in an arc to a dense film support and available from 3M Company, St.
Paul, MN, USA, under the trade name Extrusion Bonded Loop.
The fibrous mat 110 can be produced from any suitable thermoplastic polymeric material (for example, a material that is melt bondable). Those
+ 13/42 -— materials can include, for example, polyolefins, polyesters, polyamides, and various other materials. Examples of suitable polyolefins include polyethylene, polypropylene, polybutylene, ethylene copolymers, propylene copolymers, butylene copolymers, and copolymers and blends of such materials. Those skilled in the art will appreciate that the fibrous mat composition 110 can be advantageously chosen for the purpose of improving the melt bond to substrate 120. For example, at least the main surface 121 of the substrate, and at least some of the fibers of the fibrous mat , can, for example, be substantially composed of a polypropylene.
The fibrous blanket 110 can have any suitable weight basis, as desired for a particular application. Suitable weight bases can vary, for example, from at least about 20, 30 or 40 grams per square meter, to a maximum of about 400, 100 or 100 grams per square meter. The fibrous mat 110 can comprise any suitable thickness, as previously described in the present invention. The fibrous web 110 can comprise any suitable thickness. In various embodiments, the fibrous web 110 can be at most about 5 mm, about 2 mm, or about 1 mm thick. In additional embodiments, the fibrous web 110 may be at least about 0.1, about 0.2, or about 0.5 mm thick.
In some embodiments, some or all of the fibers 111 of the fibrous web 110 may comprise single component fibers. In some embodiments, the fibrous web 110 may also comprise bicomponent fibers, for example, which comprise a wrap of a material with a lower melting point that surrounds a core of material with a higher melting point. If desired, the wrap material can be chosen to improve its ability to melt bond to substrate 120. Other fibers (for example, staple fibers and the like) may be present. In some embodiments, the fibrous mat 110 does not comprise adhesives (i.e., thermo-melt adhesive, pressure sensitive adhesive, and the like) that may be present in the form of adhesive particles, binders or the like, distributed along the mat or in a main surface of the blanket. In some embodiments, the fibrous mat 110 comprises certain fibers with a composition advantageously suitable for the surface bond described herein, and others - fibers with a different composition than that of the surface bond fibers.
In certain embodiments, the fibrous mat 110 comprises an extended portion that is not overlapping with the substrate 120. (Through the methods described here, the exposed surface of the extended portion of the fibrous mat 110 may remain generally unaffected by heat exposure during the bonding process, that is, the exposed surface is not burned or turned into a glass or any similar condition indicating unacceptably high exposure to heat). This extended portion of the fibrous mat 110 can be used, for example, as a fixation area
. 14/42 by which laminate 150 can be attached to an item. Such a configuration is shown by way of example in figure 7, where at least one substrate 120 is present as a narrow strip over a wider width of fibrous mat 110. An individual piece 160 of laminate 150 can be removed by cutting along the phantom line shown, the individual piece 160 comprising an extended portion 161 which can be used to attach piece 160 to an item. In the particular embodiment shown in figure 7, an additional extended portion 162 of fibrous web 110 is provided which extends in the opposite direction to the extended portion 161, and can serve, for example, as a lifting flap in the case where the piece 160 is used as a hook lift component of a hook and loop closure system (ie, as a hook lift tab). As may be useful in this application, the exemplifying substrate of Figure 7 comprises protuberances 123 (which may be male fasteners, for example) that project from the second main surface 122 of the substrate 120.
In the particular embodiment illustrated in figure 7, substrate 120 is present as two strips over a wider width of fibrous mat 110, with a laterally extended portion of fibrous mat 110 externally delimiting each strip of substrate 120 and with an additional extended mat portion fibrous 110 laterally between the substrate strips. From this laminate, individual pieces 160 can be cut, each piece with a fixing portion 161 and a lifting flap portion 162, for example, for attaching to items such as hygiene items (for example, diapers, care products personal, and the like). The attachment of the portion 161 to an item can be accomplished by any method known in the art, for example, ultrasound joining, adhesive fixing, etc.
In summary, the bonding processes described herein involve impacting the heated fluid (i.e., gaseous fluid) against a first main surface of a first moving substrate and impacting the heated fluid against a first main surface of the second moving substrate. In some embodiments, moving substrates can be converging substrates, meaning that the substrates are moving along a converging path in which the first main surface of the first substrate comes into contact with the first main surface of the second substrate. As presented herein, the collision of the heated fluid against a first surface of a moving substrate can raise the temperature of the first surface of the substrate sufficiently for the bond to be obtained, without necessarily raising the temperature of the remaining portions of the substrate (for example, the inside the substrate and / or the second opposite main surface of the substrate) to a point sufficient to cause unacceptable physical changes or damage. In the specific case of connecting a fibrous blanket to a
* 15/42 substrate, in some embodiments, the temperature of the fluid-impacted surfaces of the fibrous mat and the substrate can be high enough to obtain the surface bond described above, for example, without causing the fibers to become embedded in the substrate , and / or without causing fusion, densification and / or solidification of the fibers immediately adjacent to the substrate surface to cause the formation of a continuous bond.
Those skilled in the art will recognize the bond described herein as a fusion bond, that is, where the molecules of the first surface material and the substrate surface material intermix while in a heated state achieved by the collision of the heated fluid and then remain intermixed through cooling and solidification. Those skilled in the art will also appreciate that the heated fluid collision methods described herein are not limited to the formation of surface-bound laminates as described in the present invention, and can be used for additional purposes, for example, to achieve a fusion bond. that does not fit the definition of the surface bond for use in the present invention, and even for purposes other than fusion bonding.
In some embodiments, the collision of the heated fluid against a first main surface of a first moving substrate and the collision of the heated fluid against a first main surface of a second moving substrate are performed simultaneously, with the collision of the heated fluid continuing substantially until the first substrate main surfaces are brought into contact with each other.
Shown in figure 8 is an example apparatus 1 that can be used at least to obtain a surface bond described above. In these embodiments, the first substrate 110 (for example, a fibrous mat) and the second substrate 120 (for example, a substrate optionally containing protuberances) are each in contact with a respective support surface during the fluid collision heated against the first main surface of each substrate. This support surface can serve to support the substrate, and can also be cooled to a certain degree (for example 100, 200, or 300 or more degrees C below the temperature of the collision of the heated fluid), in order to assist in maintaining the rest of the substrate sufficiently cold to prevent or minimize damage, melting, etc., of the substrate, during the time when the first main surface of the substrate is heated in order to facilitate surface bonding. If a substrate is discontinuous or porous (for example, if the substrate is a fibrous mat) such a support surface can also serve to obstruct the second main surface of the substrate in such a way that the collision fluid does not penetrate through the thickness of the substrate and exits through of the second
+ 16/42 main surface. Therefore, in these embodiments, heating a main surface of a substrate by colliding the heated fluid as described in the present invention, does not cover methods in which the heated fluid is impacted against a main surface of a substrate and passed through the substrate with the purpose of going out through the opposite main surface.
In some embodiments, the support surface can be provided by a support cylinder. Therefore, in the exemplary illustration of Figure 8, the second main surface 113 of the substrate 110 is in contact with the surface 231 of the support cylinder 230 during the collision of the heated fluid against the first main surface 112 of the substrate 110. Similarly, the second main surface 122 of the substrate 120 (or the outermost surface of the protuberances 123, if such protuberances are present), is in contact with the surface 221 of the support cylinder 220 during the collision of the heated fluid against the first main surface 121 substrate 120.
In some embodiments, a preheating cylinder can be used to preheat a surface of one or both of the substrates 110 and 120 prior to the collision of the heated fluid. In the exemplary illustration of figure 8, the main surface 121 of the substrate 110 is brought into contact with the surface 211 of the preheating cylinder 210 before the collision of the heated fluid against the main surface 121 of the substrate 110.
In the embodiment illustrated in figure 8, the support cylinder 220 and the support cylinder 230 combine to form a lamination contact line 222 in which the first main surface 112 of substrate 110 and the first main surface 121 of substrate 120 are placed in contact with each other while at a temperature (established by the collision of heated fluid) sufficient to cause at least one surface bond of substrates 110 and 120 to each other. As mentioned earlier in this document, it may be advantageous to make such a connection under | conditions that minimize damage, crushing and the like, to any component of | substrates 110 and 120. This can be particularly useful in the case where, as shown in figure 8, substrate 120 comprises protuberances (for example, which may be susceptible to being deformed or crushed). Therefore, support cylinders 230 and 220 can be arranged so that they operate contact line 222 at a very low pressure compared to pressures normally used in rolling materials (for which relatively high pressure is generally preferred). In various embodiments, the bonding of substrates 110 and 120 to each other can be performed with a lamination contact line pressure less than about 27 Newtons per linear cm (15 pounds per linear inch), less than about 18 Nlc (10 pli), or less than about 9 Nlc (5 pli). In other embodiments, the support cylinder 230, the support cylinder 220,
, 17/42 or both, may comprise at least one surface layer of a relatively soft material (for example, a rubber material with a hardness content of less than 70 on the Shore A scale). This relatively smooth surface layer can be obtained, for example, through the use of a cylinder with a soft surface coating permanently attached, through the use of a removable sleeve of soft material, covering the surface of the support cylinder with a resilient and relatively soft tape, and the like. If desired, the surface of one or both of the support cylinders can be staggered along the face of the cylinder to provide selectively laminating pressure at certain locations.
By exiting the laminating contact line 222, laminate 150 (which in some embodiments can be bonded by surface, bonded with thickness retention, or both) can be cooled if desired, for example, by placing one or both the main surfaces of laminate 150 in contact with a cooling cylinder, by colliding a cooling fluid against one or both surfaces of laminate 150, and the like. Subsequently, laminate 150 can be processed through any suitable blanket handling process, rolled up, stored, etc. For example, additional layers can be coated or laminated on laminate 150, individual pieces can be cut from them as described above, and so on.
As mentioned, the apparatus and connection methods described herein can be particularly advantageous for the connection of substrates comprising protrusions | easily crushed. In addition, the apparatus of connection methods described herein can be | particularly suitable for bonding porous materials such as fibrous blankets. These | blankets may comprise a self-insulating capacity such that the first main surface of the fibrous web can be heated by the collision of the heated fluid, while the remainder (second inner and main surface) of the web remains relatively cold. (Some unforeseen additional fiber-to-fiber bonds may occur in the fibrous blanket during exposure to heat). Bonding processes as described in the present invention | they can also be especially suitable for connecting fibrous blankets to a | 30 - substrate while retaining the thickness of the fibrous mat, as previously mentioned.
Those skilled in the art will appreciate that the heating of multiple substrates, for example, converging substrates, impacting the heated fluid against a first main surface of a first moving substrate and impacting the heated fluid against a first main surface of a second moving substrate (in —particular as obtained by using the nozzles described below in this document), may be suitable for many uses, including uses other than the aforementioned connection or the surface connection. For example, these methods can be used to evaporate liquids at
, 18/42 starting from substrates, modifying the surface structure of substrates through annealing or similar, promoting a chemical reaction or surface modification, drying, hardening, and / or crosslinking a coating present on the surface, and so on. The collision of the heated fluid against the first main surface 112 of the substrate 110, and the collision of the heated fluid against the first main surface 121 of the substrate 120, can be obtained through the use of the nozzle 400. A nozzle 400 of the example type shown in figure 8 is shown in greater detail in figure 9. As shown in side view in figure 9 (seen along an axis transverse to the direction of movement of the substrates 110 and 120, that is, an axis aligned with the long axes of the support cylinders 220 and 230 ), the nozzle 400 comprises at least one first fluid delivery outlet 420, through which the heated fluid can be impacted against the first main surface 112 of substrate 110, and a second fluid delivery outlet 430 through which the fluid the heated surface can be impacted against the first main surface 121 of the substrate 120. (The references of the present invention to the first outlet for fluid distribution, are second outlet for fluid distribution, etc. are used for convenience of differentiating separate outputs, etc. each other, and should not be construed as requiring the fluids distributed through the different outlets etc. different in composition). The first fluid delivery outlet 420 is supplied with heated fluid through the first fluid delivery channel 421 to which it is fluidly connected, and the second fluid delivery outlet 430 is supplied with heated fluid through the second fluid distribution channel 431 to which it is fluidly connected. In some embodiments, the nozzle 400 may comprise a single internal full space (chamber) supplied with heated fluid from an external source (not shown) via the supply line 410, with the heated fluid directed to the first and second outlets for fluid distribution 420 and 430 from the single common filled space and the first and second outlets for fluid distribution 420 and 430 therefore comprise first and second portions of a single outlet for continuous fluid distribution. Therefore, in these embodiments, the first and second fluid distribution channels 421 and 431 are portions of a single common filled space rather than being physically separate channels, and the first and second outlet portions for fluid distribution 420 and 430 they will distribute the heated fluid from a common source under similar or identical conditions (in this case, the outlet portions 420 and 430 can simply be opposite portions of a single outlet).
In alternative embodiments, the interior of the nozzle 400 can be divided (for example, by an optional interior partition 422 of Figure 9) into the first fluid distribution channel 421 and the second fluid distribution channel 431 which are physically separate and are not fluidly connected to each other. In this case, the second fluid distribution channel 431 and the second outlet for fluid distribution 430 can be supplied, via the 19/42 second fluid supply line 411, with a heated fluid that is different (for example, or (air at a different temperature, pressure, speed, etc.), from the heated fluid supplied to the first fluid distribution channel 421 and the first outlet for fluid distribution 420.! 5 Although the exemplary nozzle 400 of figures 8 and 9 is shown as a single: unit from which the heated fluid can be impacted against the first main surface 112 of substrate 110 and against the first main surface 121 of substrate 120, | it will be appreciated that the collision discussed here can be carried out, for example, through the use of two adjacent but physically separate units, one of which impacts the heated fluid through the fluid delivery outlet 420 against the first main surface 112 of the substrate 110 and the other impacts the heated fluid through the fluid delivery outlet 430 against the first main surface 121 of the substrate 120. Therefore, although the term "nozzle" is used in this document for convenience of | discussion, it should be understood that the apparatus (for example, nozzle) covers the apparatus in —which a single unit impacts the fluid against both substrates as well as a multi-unit apparatus in which one unit impacts the fluid against one substrate and the other unit (which may be a physically separate unit) impacts the fluid against the other substrate.
Typically, nozzle 400 will comprise solid (i.e., impermeable) partitions 442 and 442 'which collectively define fluid distribution tubes 421 and 431. The end ends of partitions 442 and 442' that are closest to substrate 110 can collectively define the fluid distribution outlet 420 (and may be the only elements that define the fluid distribution outlet 420 if outlet 420 does not comprise a fluid-permeable sheet (described later in detail) on its working face.
Similarly, the end ends of partitions 442 and 442 'which are closest to substrate 120 can collectively define the outlet for fluid distribution 430. Partitions 442 and 442' can be positioned generically parallel to each other (for example, similar as shown in figure 10a for partitions 542 and 542 ', which define fluid distribution channel 521 of nozzle 500 similarly to that where partitions 442 and 442' define fluid distribution channel 421 of nozzle 400), if it is desired that the fluid distribution channels 421 and / or 431 have a constant width.
Or, the width between partitions 442 and 442 'may vary if it is desired, for example, to provide a fluid distribution channel that narrows or expands as the fluid progresses along the channel.
In addition to partitions 442 and 442 ', the nozzle 400 may comprise one or more partitions 415 that define the rear portion of the nozzle 400 (away from the fluid delivery outlets). Therefore, the nozzle 400 may comprise at least partitions 442, 442 ', and 415, which collectively provide a housing in which heated fluid can be supplied by the feed line 410 (and the feed line 411, if present), with the primary, or unique, paths for the heated fluid to exit the nozzle 400 via fluid delivery outlets 420 and 430. For convenience of description, the first outlet for fluid distribution 420 is characterized by comprising a face of work 424, which can be more conveniently considered to be the surface through which the heated fluid passes as it exits outlet 420. Work face 424 can be an imaginary surface, such as an imaginary arcuate surface (for example, a section of a cylindrical surface) defined by terminal ends of partitions 442 and 442 ". Or, the work piece 424 may comprise a physical layer, for example, a perm sheet fluids, as discussed further in this document in more detail.
The second outlet for fluid distribution 430 is similarly characterized by comprising a working face 434. Each outlet and working face of the same can have a circumferential length, and a lateral width (which extends in a direction transverse to the direction of movement of the adjacent substrate, that is, extending in a direction aligned with the long axes of the adjacent support cylinder). In some embodiments, the circumferential length may be longer than the lateral width, such that the outlet is circumferentially aligned.
Although in the illustrative illustration in figure 8, the first | 20 fluid distribution outlet 420 extends along the entire circumferential length of the face of the nozzle 400 which is adjacent to the cylinder 230 (with the second fluid distribution outlet 430 extending in a similar manner over the entire length circumferentially of the face of the nozzle 400 which is adjacent to the cylinder 220), in some embodiments, each face of the nozzle 400 may comprise multiple outlets for separate fluid distribution.
These multiple outlets can be defined by laterally oriented dividers and can be spaced along the circumferential length of one face of the nozzle, as shown in Example Set 3. The first outlet for fluid distribution 420, and the second outlet for fluid distribution 430, are in a divergent relationship.
The term divergent relation can be defined by means of the axis 423 drawn normal to the working face 424 of the first outlet for fluid distribution 420, and the axis 433 drawn normal to the working face 434 of the second outlet for fluid distribution 430, as described in figure 9. The term divergent relation means that the normal axis 423 of the first outlet for fluid distribution 420, and the normal axis 433 of the second outlet for fluid distribution 430, when extended from their respective working faces in one direction moving away from nozzle 400, they do not intersect regardless of how extended they are.
The term divergent relation also means that the normal axis 423 and the 21/42 normal axis 433 are oriented at least 25 degrees apart (for example, in figure 9, the normal axis 423 and the normal axis 433 are oriented approximately 90 degrees apart). In various embodiments, the normal axes 423 and 433 are oriented at least about 40, at least about 60, or at least about 80 degrees apart. In additional embodiments, the normal axes 423 and 433 are oriented at most about 140, at most about 120, or at most about 100 degrees apart.
Those skilled in the art will realize that in modalities with arched fluid distribution outlets (described in more detail below), the relative orientation of the normal axes 423 and 433 may vary with the circumferential location along each outlet in which the normal axis is positioned. In these cases, the denotation that two | outlets for fluid distribution are in a divergent relationship means that at least the portions of the two outlets are in close proximity to each other (for example, the portions of outlets 420 and 430 that are proximal to the protrusion 435) are in a relationship divergent. In some cases, for example, where at least one of the fluid delivery outlets is circumferentially extended to form, for example, an almost semi-cylindrical shape, a portion of such fluid delivery outlet that is distal to the other delivery outlet of fluids (for example, distal to protrusion 435) may not be in a divergent relationship with any or any of the portions of the other outlet for fluid distribution. This case will be described below with reference to Examples 1-3. However, in these cases, as long as the condition described above is satisfied in which at least the portions of the two outlets that are in close proximity to each other are in a divergent relationship, the outlets for fluid distribution are still considered to be in a relationship divergent as defined here.
The first and second outlets for fluid distribution 420 and 430 arranged in a divergent relationship as described in this document can be particularly advantageous for directing heated fluid over two converging substrates. In particular, these outlets for fluid distribution in a divergent relationship allow the nozzle 400 to be placed closely adjacent to a lamination contact line established by support cylinders, for example, as described in figures 8 and 9. Although it is discussed primarily in the context of connecting substrates together, it will be appreciated that the use of outlets for fluid distribution arranged in a divergent relationship may find other uses in heating substrates for other purposes.
In the exemplary illustration of Figures 8 and 9, the first outlet for fluid distribution 420 is arched with the work face 424 which is generally congruent
- 22/42 (That is, it has a generally similar and parallel shape) to the adjacent surface of the support cylinder 230. This can be advantageous in allowing the working face 424 of the first outlet for fluid distribution 420 to be placed in close proximity with the support cylinder 230. Therefore, in various modalities, in the operation of the nozzle 400, the working face 424 of the first outlet for fluid distribution 420 can be less than about 10, 5 or 2 mm from the first main surface 112 of substrate 110, at the closest approach point. Similarly, in the exemplary illustration of Figures 8 and 9, the second fluid delivery outlet 430 is arched with a work face 434 that is generally congruent with the adjacent surface of the support cylinder
220. 1This may be advantageous in allowing the working face 434 of the second fluid delivery outlet 430 to be placed in close proximity to the support cylinder
220. In various embodiments, in the operation of the nozzle 400, the working face 434 of the second outlet for fluid distribution 430 can be less than about 10, 5 or 2 mm from the first main surface 121 of the substrate 120, at the point approach.
In particular embodiments, the first fluid delivery outlet 420 is arched to a working face 424 that is generally congruent to the adjacent surface of the support cylinder 230, and the second fluid delivery outlet 430 is arched to a working face 434 which is generally congruent with the adjacent surface of the support cylinder 220. This can allow the nozzle 400 to be positioned in such a way that each working face of each outlet for fluid distribution is very close to the first main surface of their respective substrates.
In embodiments where it is desired that the outlets 420 and 430 are closely fitted to the adjacent surface of the support cylinders (cylindrical), the working face of each outlet may comprise an arcuate shape that is a section of a generally cylindrical surface with a radius of curvature compatible with that of the surface of the support cylinder to which the outlet must be fitted. In situations where the support cylinder 220 and the support cylinder 230 have the same diameter, the two fluid distribution outlets can be symmetrical with the same radius of curvature. However, if the support cylinder 220 and the support cylinder 230 have different diameters, as shown in figures 8 and 9, the curvature of the first outlet for fluid distribution 420 may be different from that of the second outlet for fluid distribution 430 .
The circumferential length of each arcuate outlet can be different if desired. For example, in figures 8 and 9, the circumferential length of the outlet 420 is longer than that of the outlet 430. Optionally, one or both of the outlets may comprise an adjustable plug (not shown in any figure) which may be the. 23/42 adjusted in order to change the circumferential length of the outlet. This plug can be used to adjust the residence time of a substrate in the collision of heated fluid, for example, regardless of the speed of movement of the substrate. In the operation of device 1, the position of the obturator, as well as other process variables such as fluid temperature, fluid flow rate, support cylinder temperatures, etc., can be manipulated as desired, for example, with a view to linear speed, thickness and other properties of the particular substrates being processed.
Fluid delivery outlet 420 and fluid delivery outlet 430 can be chosen as they have any suitable side width. For use in the present invention, lateral means the direction transverse to the direction of movement of a substrate to be heated and in a direction parallel to the long axis of the support cylinder (that is, the direction inside and outside the plane in figures 8 and 9) In some embodiments, particularly those where at least one of the substrates to be connected is in the form of a narrow strip (for example, as in the example embodiment of figure 7), it may be desirable that the lateral width of the outlet for fluid distribution is relatively narrow (for example, chosen considering the width of the substrate to be bonded). In this case, it may be additionally desirable for the fluid delivery outlet to be stretched (for example, circumferentially stretched) in a direction substantially aligned with the long axis, and in the direction of movement, of the substrate to be connected (keeping in mind that the axis long and the direction of movement of the substrate can be arched when the moving substrate is supported by a support cylinder). For example, in Figure 9, the working face 424 of outlet 420 is circumferentially elongated along an axis that is substantially aligned with the shaft and the direction of movement of the substrate 110. A circumferential end of the first outlet for fluid distribution 420, and a circumferential end of the second fluid delivery outlet 430, can be positioned adjacent to each other to form a protruding protrusion 435, as shown in an exemplary manner in figure 9. The angle of approach of the two exits to each other can be such that the projection 435 takes the form of a relatively pointed protuberance, with the working face 424 of the outlet 420, and the working face 434 of the outlet 430, being at an acute angle to each other at their closest approach or contact point . This projecting design can advantageously allow the projection 435 to be positioned deeply in the region of converging contact line between the support cylinders 220 and 230 and can allow the heated fluid to be impacted against the substrates substantially until the moment in which the substrates come into contact with each other. In many
+ 24/42 modalities, at their closest approach point, the nearest approach work face 424 of exit 420 and the work face 434 of exit 430 can be at an angle to each other less than about 70 , less than about 50, or less than about 30 degrees.
In some embodiments, the work surface of an outlet for fluid distribution may not be congruent with the support cylinder to which it is attached. For example, one or both of the outlets 420 and 430 may be generically flat (smooth) rather than arched as shown in figures 8 and 9. Although this may mean that the outlet for fluid distribution may not be able to be positioned as close to the support cylinder, and the distance from the work face to the support cylinder can vary along the length of the fluid distribution outlet, it may still be acceptable in some cases.
As mentioned, the working face of an outlet for fluid distribution can be opened; or, it may comprise a fluid-permeable sheet through which the heated fluid can be passed. This fluid-permeable sheet can make the heated fluid flow through the outlet more uniform, for example, along the circumferential length of the outlet. In addition, depending on the characteristics of the sheet, it may redirect the fluid in some way by moving away from its original flow direction through the fluid distribution channel. For example, with reference to figure 9, the heated fluid from supply 410 may flow through the fluid distribution channel 421 in a direction generally aligned with the long partition axis 422, however, when passing through a fluid-permeable sheet in the working face 424 of the fluid delivery outlet 420 the fluid can be at least somehow directed to the flow in a direction more strictly aligned to the normal axis 423 of working face 424 (for example, as shown by the multiple arrows denoting the fluid flow in figure 9). This design can have advantages over causing the heated fluid to be impacted against substrate 110 in a direction closer to the normal direction of the substrate, opposing the collision against substrate 110 in a more tangential orientation. Similar considerations apply to the presence of a fluid-permeable sheet on the working face 434 of outlet 430. Internal deflectors (not shown in the figures) can also be used within the fluid distribution channels 421 and / or 431 to direct the heated fluid in a desired direction.
In various embodiments, the fluid-permeable sheet may comprise through openings which collectively provide the sheet with a percentage of open area of at least about 20, at least about 30, or at least about 40. In additional embodiments, the fluid-permeable sheet may comprise a percentage of open area of at most about 90, at most about 80, or at most about 70. In specific and 25/42 - specific ways, the fluid-permeable sheet may comprise a perforated screen with through holes of a diameter at least about 0.2 mm, at least about 0.4 mm, or at least about 0.6 mm. The fluid-permeable sheet may comprise, for example, a perforated web with through holes having a maximum diameter of about 4 mm, a maximum of about 2 mm, or a maximum of about 1.4 mm. The through holes can be in the form of elongated slits, for example laterally elongated, as described below in Example 1. The combination of the percentage of open area and the size of the through hole can be chosen to accentuate the uniform heating of the substrate. The screen can be composed of any material with sufficient durability and temperature resistance for the uses shown here. For example, a metal screen may be suitable.
The heated fluid can leave the working face of the outlet for fluid distribution at any suitable linear speed. The speed can be affected and / or determined by the volumetric flow rate of the heated fluid supplied to the nozzle 400 by the feed line 410 (and the feed line 411, if present), by the size of the outlets for fluid distribution, by the percentage of open area and / or the diameter of the through holes in a fluid-permeable sheet (if present) on the working face of the outlet, etc. As mentioned, in the case where partition 422 is present, during the operation of the apparatus 1 the linear velocity of the heated fluid leaving the nozzle 400 through outlet 430 can be controlled independently of that which exits through the outlet
420. Linear speed will generally be in the low sub sonic range, for example, less than Mach 0.5, typically less than Mach 0.2. Often, the linear speed will be in the range of a few meters per second; for example, less than 50, less than 25, or less than 15 meters per second. As such, the apparatus and heated fluid collision methods used herein can be distinguished from the use of, for example, hot air knives, which generally depend on a linear velocity that approaches or exceeds the sonic velocity.
The area of the work faces 424 and 434 of the exits 420 and 430, respectively, can be chosen in order to heat an area of desired size, and can be chosen taking into account the characteristics of the substrates to be heated (for example, its width, thickness, density, heat capacity, etc.). Often, outputs with working faces in the range of about 5 to 50 square centimeters can be used. The volumetric flow rate of the heated fluid, and the temperature of the heated fluid, can be chosen as desired. For melt bonding applications, the temperature of the heated fluid can be chosen to be at least equal to, or in some way greater than, the “softening point or melting point of a component of the substrates.
Any suitable heated gaseous fluid can be used, with ambient air being a convenient choice. However, dehumidified air, nitrogen, an inert gas,
26/42 or a gas mixture chosen for having a specific effect (for example, the promotion of binding capacity, hydrophobic capacity, etc.) can be used as desired. The fluid can be heated by an external heater (not shown in any figure) before being distributed to the nozzle 400 through the supply line 410 (e411, if present). In addition, or instead, the heating elements can be provided inside the nozzle 400; or additional heating (eg resistance heating, infrared heating, etc.) can be applied to the nozzle
400. Although the heating of the substrates and / or the bonding of the substrates as described in the present invention can be carried out without any special handling of the fluid after it has been impacted against the substrates (as evidenced by Example Set 3), in certain embodiments , it may be advantageous to provide local removal of the impacted fluid. Local removal means that the fluid that has been impacted against the surface of a substrate through a nozzle is actively removed from that of the local vicinity of the fluid impact nozzle. This must be contrasted with processes in which the impacted fluid is passively allowed to escape from the local surroundings of the nozzle, to be dissipated in the surrounding atmosphere or removed by a device (for example, a cover, cover, duct, etc.) that is positioned at a distance (for example, at least one decimeter) away from the fluid impact nozzle. This local removal can be achieved through the use of a nozzle of the general type previously described in this document, which comprises a fluid distribution channel with an outlet for fluid distribution, with the addition of at least one fluid capture inlet that is locally positioned in relation to the outlet for fluid distribution. Locally positioned means that at its point of approach closest to each other, the fluid capture inlet is located less than 10 mm from the outlet for fluid distribution. In various modalities, at its closest approach point, the fluid capture inlet is located less than about 5 mm, or less than about 2 mm, from the fluid distribution outlet. The fluid capture port is in fluid communication with a fluid removal channel, through which the fluid that has been captured by the fluid capture port can be actively removed (for example, via an exhaust line connected fluidly to an external suction blower, not shown in any figure). The fluid capture inlet can locally remove a substantial volume percentage of the impacted fluid from the local surroundings of the nozzle before the impacted fluid is able to leave the local surroundings of the substrate and irreversibly disperse in the surrounding atmosphere so that it is not more locally removable. In various embodiments, at least about 6%, at least 27/42 about 80%, or substantially the entire volumetric flow of the impacted fluid is locally removed by the apparatus and methods described herein.
The nozzle 500 with a locally positioned fluid capture inlet is shown in a representative manner in figure 10a, which consists of a partial cross-sectional view along the machine direction of the substrate 100 as it passes adjacent to the nozzle 500 (with the direction of movement of the substrate 100 being out of plane). For the sake of simplicity of description, Figure 10a shows only a single fluid distribution channel 521, a single outlet for fluid distribution 520, and a single substrate 100 (in contact with the support surface 201, for example, of the support cylinder 200), however, it should be understood that when used to impact the heated fluid against two converging substrates in a similar way to that described for nozzle 400, nozzle 500 will comprise two fluid distribution channels, two outputs for fluids, etc., as will be discussed in greater detail in relation to figure 11. Although in the exemplary embodiment of figure 10a, the fluid distribution outlet 520 and the fluid distribution channel 521 thereof, and the fluid capture inlets 540 / 540 'and fluid removal channels 541/541' of these, are shown as a unit, with common partitions 542 and 542 'between them, it should be understood that the impact and removal of fluids discussed here can be performed through the use of two or more adjacent units, however, physically separated, at least one of which impacts the heated fluid through the fluid distribution outlet 520 and at least one of these captures the impacted fluid locally through the 540 or 540 "fluid capture port. Therefore, although the term “nozzle” is used in this document for the sake of convenience of discussion, it should be understood that the apparatus (for example, nozzle) described herein encompasses the apparatus in which a single unit both impacts the fluid and captures the impacted fluid, as well as the multi-unit apparatus in which one or more units impact fluid and one or more additional units (which may be physically separate units) capture the impacted fluid.
Similar to the nozzle 400, the nozzle 500 comprises an outlet for dispensing — fluid 520 which comprises a working face 524 (which in this case comprises a perforated screen 525), with the outlet for fluid distribution 520 being connected in a manner fluid to the fluid delivery channel 521 (of which only the portion adjacent to the fluid delivery outlet 520 is shown in figure 10a). In addition, the nozzle 500 comprises fluid capture inputs 540 and 540, each of which is locally positioned in relation to the fluid distribution outlet 520. Fluid capture inputs 540 and 540 'are fluidly connected to the channels fluid removal 541 and 541 ', respectively.
In the configuration example shown, the capture inputs of the 28/42 fluids 540 and 540 'flank laterally (that is, they are located on either side, in a direction transversal to the direction of movement of the substrate 100, for example, in a direction along the long axis of the support cylinder 200) the outlet for fluid distribution
520. Similarly, fluid removal channels 541 and 541 'flank laterally the fluid distribution channel 521, being separated from it only by (solid) partitions 542 and 542', respectively. Therefore, fluid removal channel 541 is defined on one side by partition 542, and on the other side by partition 543 (which, in this embodiment, comprises the external nozzle compartment 500 in this area). Similarly, fluid removal channel 541 'is defined by partitions 542' and 543 ", again with reference to the simplified illustration of an outlet for distribution and a substrate in figure 10a, when active suction is applied to the removal channels of fluids 541 and 541 '(for example, via an external suction blower or blower), a substantial volume percentage of the heated fluid exiting the working face 524 of the fluid delivery outlet 520 and impacted against the first main surface 101 of the substrate 100, can be locally captured by the fluid capture ports 540 and 540 'and removed via fluid removal channels 541 and 541 ". It has been found that such local capture of impacted fluid can alter fluid flow patterns after, during, or possibly before it impacts against surface 101 of substrate 100. For example, such local capture can modify, reduce or substantially eliminate the fluid flow stagnation phenomena where the fluid impacts against the substrate so that it drastically reduces or even interrupts the flow of fluid in certain locations. In changing flow patterns, local capture can advantageously modify (for example, increase) the heat transfer coefficient between the impact fluid and the substrate at certain locations and / or can provide a uniform heat transfer over a period of time. wider area of the substrate. As evidenced by Examples 1-2, the local capture of impacted fluid can additionally allow the heated, lower temperature fluid, for example, considerably lower, to be used while still heating the substrates sufficiently to allow a bond, compared to the fluid temperature necessary impact in the absence of such local catch. This local capture can also allow for a faster linear speed of the substrates to be used.
The working faces 544 and 544 'of the fluid capture inlets 540 can be approximately positioned even with the working face 524 of the fluid delivery outlet 520, such that the working faces 544, 544' and 524 are generally equidistant from the surface 101 of the substrate 100, as represented by the distance 545 in figure 10a (in the design of figure 10a, the working faces 544 and 544 'of the fluid capture inlets 540 and 540' comprise imaginary surfaces along the
. * 29/42: instead of fluid-permeable screens). The nozzle 500 can be positioned such that the working face 524 of the fluid delivery outlet 520, and the working faces 544 and 544 'of the fluid capture inlets 540, are positioned within about 10, about 5, or about 2 mm, from the first main surface 101 of substrate 100. The end ends (closest to substrate 110) of partitions 542 and 543 can be generally equidistant from substrate 100, as shown in figure 10a. Or, the terminal end of the outward flanking partition 543 can be extended closer to substrate 110, which can improve the capture of the fluid impacted by the fluid capture inlet 540 (similar considerations apply to the fluid capture inlet 540).
Figures 10a, 10b and 10c illustrate modalities in which the working faces 544 and | 544 'of the fluid capture ports 540 and 540' are open and do not comprise a perforated screen or any other type of fluid permeable sheet. In these instances, the working face of a fluid capture inlet can be primarily defined by | 15 terminal ends of the partitions. For example, the work face 544 can be defined at least in part by the end ends of partitions 543 and 542, for example, in combination with the end ends of the partitions extending laterally not shown in figure 10, such as compartment 415 shown in figure 9). However, in various embodiments, a fluid-permeable sheet may be provided on the working face of one or more fluid capture inlets. This fluid-permeable sheet may comprise similar properties (for example, percentage of open area etc.) to those of a fluid-permeable sheet provided on the working face of the fluid distribution inlet to which the fluid capture outlet is locally positioned. , and may be a continuation of the fluid-permeable sheet of the fluid delivery inlet (for example, as shown in Example 1). In other embodiments, the fluid-permeable sheet of the fluid capture inlet may comprise different properties, and / or be composed of different materials, in relation to the fluid-permeable sheet of the fluid distribution inlet.
Figure 10a illustrates an embodiment in which the configuration of the nozzle 500, the distance from the nozzle 500 to the substrate 100, the speed of the impact fluid used, etc., combine to provide that substantially all of the fluid leaving the outlet 520 and impacts against substrate 100 to be captured through inlets 540 and 540 'before the impacted fluid is able to penetrate laterally beyond the limits of inlets 540 and 540' to any significant extent. This phenomenon is represented by the arrows that denote the direction of the fluid flow in figure 10a. (Of course, some small portion of the fluid that exits through outlet 520 can be removed through ports 540 or 540 'before impacting substrate 100). Figure 10b illustrates a modality in which the nozzle 500 is operated in such a way that the 30/42 is such that some portion of the impacted fluid is able to penetrate laterally beyond the limits of the inlets 540 and 540 '(and therefore can be mixed locally with ambient air to at least a small extent), however, in which the suction provided by the capture inlets 540 and 540 'is strong enough that substantially all of the fluid | 5 impacted is still captured by capture entrances 540 and 540 ". Figure 10c illustrates a | modality in which nozzle 500 is operated in such a way that substantially all the impacted fluid is captured by capture entrances 540 and 540 ', and in which some portion of the ambient air is also captured by the capture inlets (the ambient air flow in figure 10c is indicated by the dashed arrows). When the nozzle 500 is operated in this way, in various ways, the volumetric flow rate of the captured ambient air can vary up to about 10%, up to about 20%, or up to about 40%, of the volumetric flow rate of the captured impacted fluid. | Those skilled in the art will appreciate that through the methods of the present | invention, the impacted fluid can be circulated at least slightly laterally beyond — the limits of the fluid capture inlets and still locally captured by the fluid capture inlets and removed. n of the nozzle 500 and the operating parameters of the system (for example, flow rate of the heated fluid, the suction applied through the fluid removal channels, etc.) can change the extent to which the impacted heated fluid is able to penetrate laterally beyond the limits of the fluid capture inlets before being captured by the capture inlets, and / or can change the extent to which ambient air is captured in addition to the impacted fluid, either or both of which can advantageously improve the uniformity of the experienced heating by substrate 100.
Examining figures 10a, 10b, and 10c, the elements skilled in the art can perceive that in these exemplary illustrations, the outlet for fluid distribution 520 is only surrounded by the fluid capture inlets 540 and 540 'laterally, having no provisions for the fluid capture inlets surrounding the fluid delivery outlet 520 in the direction of movement of the substrate 100 in order to completely surround the perimeter of the fluid delivery outlet 520. However, similarly as discussed with respect to nozzle 400 , and as discussed below in relation to figure 11, the inlets and outlets of the nozzle 500 may comprise circumferentially elongated arcuate shapes with the elongated axis of the inlets and outlets aligned in the direction of movement of the substrate 100. Therefore, in various modalities, providing the Fluid capture inlets 540 and 540 'that laterally flank the outlet for distribution of fluids520 can sr sufic ient to surround at least about 70%, at least about 80%, or at least about 90%, of the perimeter of the fluid distribution outlet 520 with the fluid capture inlets. The elements versed in the technique will also evaluate the. 31/42 that when using the nozzle 500 to connect two substrates as described in detail with reference to figure 11, two fluid distribution outlets, each laterally flanked by the fluid capture inlets, can be positioned at their circumferential end ends in close proximity, which, for combined exits, will additionally minimize the exit area that is not surrounded by an entrance | capture fluid).
Although figures 10a, 10b, and 10c show only a single fluid capture input and a single substrate for convenience of describing the basic premise of local fluid capture, it is understood that the nozzle 500 can be used to impact o | 10 fluid heated against two converging substrates and locally removing the impacted fluid | local nozzle surroundings. This modality is described in an exemplary manner in figure 11. In the illustrated modality, the nozzle 500 comprises the first outlet for distribution - of fluids 520 with a working face 524, with outlet 520 being fluidly connected to the first distribution channel. of fluids 521, and laterally flanked by the first fluid capture inlets 540 and 540 'which are fluidly connected to the first fluid removal channels 541 and 541' (all as described in relation to figure 10a).
The nozzle 500 further comprises a second fluid delivery outlet 550 with a working face 554, the outlet 550 of which is fluidly connected to the second fluid distribution channel 551, and laterally flanked by the second fluid capture inlets 560 and 560 'with the working faces 564 and 564 respectively and which are fluidly connected to the second fluid removal channels 561 and 561' respectively. All of these features are analogous to the nozzle 400 in figure 9, with the addition of the fluid capture inlets and fluid removal channels. As such, fluid distribution channels 521 and 551 can be considered to be substantially equivalent to fluid distribution channels 421 and 431 of nozzle 400, and fluid distribution outlets 520 and 550 can be considered to be substantially equivalent to outlets for fluid distribution 420 and 430 of the nozzle 400. Therefore, it is understood that the relevant descriptions of the resources of the nozzle 400, for example, the circumferentially elongated and / or arched nature of the outlets, their - positioning close to the substrate, the layout of the outlets to form a protruding protrusion 535, etc., they are applied in the same way as the nozzle 500 features. In particular, the fluid delivery outlets 520 and 550 of the nozzle 500 are in a divergent relationship as previously described. In particular embodiments, the fluid capture inlets 540 and 540 'can be congruent to the fluid distribution outlet —520, all of which can be congruent to the adjacent surface 201 of the support cylinder 200 (ie, the arched shapes of all of these elements can be similar and generally parallel to each other). Similar considerations apply for capture entries
The 32/42 of fluids 560 and 560 ', and outlet for fluid distribution 550, in relation to each other and to the surface 206 of the support cylinder 205. In figure 11, only one heated fluid supply line (510) is shown, and fluid distribution channels 521 and 551 are shown comprising portions of a single full space without partitions (analogous to partition 422 of nozzle 400) between them. It is understood that such a partition can be used if desired, and a heated fluid supply line can be used for a fluid distribution channel 551 that is separate from the heated fluid supply line used for the fluid distribution channel 521 (similarly to that described for mouthpiece400).
At least one fluid exhaustion line 511 is used to remove the captured fluid from the fluid removal channels of the nozzle 500. In the illustrated embodiment, fluid removal channels 541 and 561 comprise portions of a single fluid removal channel, there are no split partitions between them. Therefore, in this embodiment, a single fluid exhaust line can be used to remove captured fluid from channels 541 and 561. If a partition is provided between fluid removal channels 541 and 561, separate fluid exhaust lines can be used. provided for each fluid removal channel. Similar considerations apply to channels 541 'and 561. If desired, separate fluid exhaust lines can be connected to fluid removal channels 541 and 541 ”. Alternatively, the passages can be provided inside the nozzle 500 (for example, passing laterally through the fluid distribution channel 521), which interconnect the fluid removal channels 541 and 541 ', in such a way that a single exhaust line from fluids can be used for both, Similar considerations apply to channels 561 and 561.
The fluid delivery outlet 520 can be used to impact heated fluid against the main surface 101 of the substrate 100, while the substrate 100 is in contact with the support surface 201 (for example, of the support cylinder 200). Similarly, the fluid delivery outlet 550 can be used to impact the heated fluid against the main surface 106 of the substrate 105, while the substrate 105 is in contact with the support surface 206 (for example, the support cylinder 205). These operations can be conducted in a similar manner to that described for the nozzle 400, except that the fluid capture inlets 540, 540 ', and 560 and 560' are used as described previously, in order to capture the impacted fluid locally. .
In some cases, it may be desirable to provide multiple laterally spaced fluid delivery outlets, each fluidly connected to a fluid delivery channel. As described elsewhere in this document, 'laterally means a direction transverse to the direction of movement of the substrate to be heated, for example, along the long axis of a support cylinder. Figure 12 shows each configuration example, again in the simplified context of a single substrate 100 with the direction of movement of the substrate being outside the plane of figure 12. The exemplary nozzle 600 comprises a first and a second laterally spaced fluid distribution outlets 620 and 620 'with working faces 624 and 624', respectively, and fluidly connected to fluid distribution channels 621 and 621 ", respectively. In the illustrated embodiment, working faces 624 and 624 'comprise perforated screens 625 and 625 respectively. External fluid removal outlets 640 and 640 'are provided which flank the fluid distribution outlets 620 and 620 "laterally. An additional internal fluid capture input 670 is also provided which is laterally sandwiched between the fluid distribution outlets 620 and 620 '. Fluid capture inlets 640, 640 ', and 670 comprise working faces 644, 644', and 674, respectively, and are fluidly connected to fluid removal channels 641, 641 'and 671 respectively. External fluid removal channels 641 and 641 'are separated from fluid distribution channels 621 and 621' by partitions 642 and 642 ", respectively. External fluid removal channels 641 and 641 'are further defined by partitions 643 and 643 ', respectively, which may comprise part of the nozzle compartment 600 - at these locations The internal fluid removal channel 671 is separated from the fluid distribution channels 621 and 621' by partitions 672 and 672 ', respectively.
The descriptions of the various fluid distribution and removal channels, fluid distribution outlets and fluid capture inlets provided above in relation to nozzles 400 and 500, are applicable to various channels, outlets and inlets of the nozzle 600. And, of course, although shown (for the sake of convenience of description) in figure 12 in relation to a single substrate 100, it should be understood that when used to impact heated fluid against the two converging substrates in a similar way to that described for the nozzle 400 and the nozzle nozzle 500, nozzle 600 will comprise channels, outlets, inlets, etc., as needed to impact heated fluid against the two substrates. In particular, —obocal600 may comprise two laterally spaced pairs of fluid delivery outlets with each outlet of a given pair being in a divergent relationship, and with the laterally spaced pairs of fluid delivery outlets being flanked laterally outward by pairs of fluid capture entrances and having an additional pair of laterally sandwiched fluid capture entrances between them.
As shown in figure 12, the heated fluid that exits the working faces 624 and 624 'of the fluid distribution outlets 620 and 620' and impacts against the substrate 100 is locally captured by the fluid capture inlets 640, 640 'and 670 The elements and 34/42 skilled in the art will assess that interposing the internal fluid capture input 670 laterally between the fluid distribution outlets 620 can reduce or eliminate any stagnation points that might otherwise result from the fluid collision from the two outlets. Designs of the type depicted in Figure 12 can provide improved uniformity in heating wide substrates. In addition, designs of this type can be advantageous in the case where it is desirable to heat two substrates in parallel strips (for example, to produce laminates of the type shown in figure 7). In this case, the fluid delivery outlet 620 can be generally centered on one strip of substrate, and the fluid delivery outlet 620 'can be centered on the other.
The basic design of the nozzle 600, where multiple laterally spaced fluid delivery outlets are used, with the fluid capture inlets flanked outwardly flanking the fluid delivery outlets, and an additional fluid capture inlet is positioned laterally between the fluid distribution outlets, it can be extended as desired. That is, a nozzle can be produced with any number of fluid distribution outlets (with its long axis generally aligned in the direction of movement of the mat), laterally interspersed in an alternating manner with the fluid capture inlets. As mentioned earlier, multiple fluid distribution outlets and physically separate fluid capture inlets can be provided, for a similar purpose. Any design of this type can allow substrates of wide width to be heated using the methods described here.
Those skilled in the art will appreciate that although the apparatus and methods for local removal of impacted fluid may be particularly advantageous for applications such as heating substrates to obtain a surface bond as described in the present invention, many other uses are possible.
Examples Example 1 A continuous spinning non-woven blanket was obtained from First Quality Nonwovens under the trade name Spunbond 50 gsm (SSS). The blanket was 50gsm with a stitch pattern of 15% stitch connection and a width of 100 mm, and was composed of polypropylene. A substrate was obtained from 3M Company, St. Paul, MN, USA under the trade name CS600 (of the general type described in US patent 6000106). A first surface of the substrate was generally smooth and the second surface of the substrate had protrusions at a density of approximately 15.89MPa (2300 per square inch), (the protrusions being male fastening elements with a generally enlarged disc-shaped head ). The thickness of the substrate was approximately 100 microns (not counting the height of the 35/42 "protuberances) and the height of the protuberances was approximately 380 microns. The support and protuberances were built entirely and both composed of polypropylene / polyethylene copolymer The substrate was obtained as elongated strips each 24 mm wide.
A blanket handling apparatus with a lamination contact line was fitted in a similar manner to that shown in figure 8. Two elongated strip substrates were attached to the first surface of a single non-woven blanket as described in the present invention. Although for the sake of convenience the following description has occasionally been formulated in terms of a substrate, it is understood that two identical substrates were identically handled, moving in parallel.
When using the device, the substrate was oriented on a chrome preheating cylinder with a radius of 10.2 cm (analogous to cylinder 210 in figure 8) with a first surface of the substrate (that is, the surface opposite the surface that supports protrusions) in contact with the surface of the preheating cylinder. The preheating cylinder was internally heated by hot oil to comprise a nominal surface temperature of approximately 118 degrees C. Upon obtaining steady state operating conditions, it was found that a first substrate surface reached a temperature of approximately 113 degrees C (as monitored by a non-contact thermal measurement device).
From the preheating cylinder, the substrate traveled a distance of approximately 5.1 cm to a first support cylinder (analogous to cylinder 220 in figure 8) with a radius of 3.2 cm, which was not actively cooled or heated . On its surface, the cylinder comprised a surface layer with a nominal thickness of 0.64 cm of silicone rubber impregnated with aluminum particles. The surface layer comprised a Shore A hardness of 60. The surface layer comprised two elevated plateaus that extend completely circumferentially around the cylinder (the plateaus were raised approximately 2.2 mm above the surrounding surface of the cylinder), each one with a width of approximately 27 mm, with the lateral distance (along the —facedo cylinder, in a direction aligned with the long axis of the cylinder) between its edges close to approximately 8 mm. The parallel displacement substrates were oriented on the plateaus of the first support cylinder in such a way that the mushroom-shaped heads of the protuberances on the second substrate surface came into contact with the plateau surface. (The substrates were raised over the plateaus to minimize the chances of non-woven fabric contacting the surface of the first support cylinder.) After contacting the surface of the first support cylinder, the substrates traveled
CG 36/42 circumferentially an arc of approximately 180 degrees around the first support cylinder to be heated and connected as described in the present invention. When using the device, the non-woven blanket was oriented on a second support cylinder, with a radius of 10.2 cm (analogous to cylinder 230 in figure 8). The second support cylinder comprised a metal surface that was controlled by internal fluid circulation at a nominal temperature of 38 degrees C. The non-woven blanket circumferentially ran an approximately 90 degree arc around the second support cylinder to be heated and connected as described in the present invention. The trajectory of the non-woven mat was aligned with the trajectories of the two substrate strips in such a way that when the two substrates came into contact with the non-woven mat in the contact line between the two support cylinders, the substrate strips were lined up with the non-woven blanket.
The support cylinders were positioned in a horizontal pile, similar to the arrangement shown in figure 8. A hot air current impact nozzle capable of capturing / removing locally impacted air, was constructed and placed vertically above the cylinder of support, adjacent to the contact line, in a manner similar to the placement of the nozzle 400 in figure 8. As seen from the side along an axis transversal to the movement of the mat (that is, as seen in figure 8), the nozzle comprised a first surface and a second surface, the first and second surfaces being in a divergent relationship (as defined above). Each surface comprised a generally cylindrical section, with the curvature of the first surface generally compatible with the curvature of the first support cylinder (with the radius of curvature of the first surface being approximately 3.20cm) and the curvature of the second surface generally compatible with the curvature of the second support cylinder (with the radius of curvature of the second surface being approximately 10.2 cm). The circumferential length of the first surface was approximately 75 mm and the circumferential length of the second surface was approximately 50 mm. The two surfaces are on a protruding projection similar to the projection 435 in figure 9.
As seen from a direction aligned with the movement of the two substrate strips, the first diverging surface of the nozzle comprised two air distribution outlets, each of which had a side width of approximately 25 mm. The two air distribution outlets were flanked laterally outward by the two air intake ports, having a side width of approximately 21 mm.
—Suggested laterally between the two air distribution vents was an additional air capture inlet, having a side width of approximately 4 mm. A perforated metal screen comprising elongated slit openings was positioned so that the 37/42 extends transversely along the first diverging surface in order to cover the two air distribution outlets and the air capture inlet between the same, however, not covering the two air capture inlets that flank laterally outward. The slit openings were elongated in the lateral direction, were approximately 0.9 mm wide, and were circumferentially spaced at a center-to-center spacing of approximately 3.0 mm. The perforated metal screen comprised a percentage of open area of approximately 28%. Therefore, the first surface of the nozzle comprised a configuration similar to that shown in figure 12, except that the perforated metal screen defined the sandwiched air capture in addition to defining the work surfaces of the air distribution outlets. : When viewed from a direction aligned with the movement of the non-woven blanket, the second divergent surface of the nozzle comprised a similar arrangement of two air distribution vents, two air capture inlets that flank laterally, and an inlet of air capture laterally sandwiched. The lateral widths of the exits and inlets were the same as those of the first diverging surface. The second divergent surface comprised an adjustable shutter that extended laterally in order to laterally cover the width of both the air distribution vents and those that can be | moved circumferentially along the second surface in order to control the circumferential length of the air distribution outlets. The plug was positioned in such a way that the circumferential length of the air distribution outlets on the second divergent surface was approximately 40 mm. The perforated metal screen described above covered the two air distribution outlets and the air capture inlet between them on the second divergent surface, similarly to the first divergent surface.
All diverging air inlets and outlets on the first and second diverging surfaces were fluidly connected to the air distribution channels and the air removal channels, respectively. The air distribution vents were all fed by the same air distribution duct attached to the nozzle, such that the substrates, and the non-woven blanket, received air at generally similar temperatures.
The temperature and volumetric flow rate of the heated air supplied to the nozzle could be controlled as desired (using a heater available from Leister, of Kaegiswil, Switzerland, under the trade name Lufterhitzer 5000). The volumetric rate of removal of captured air (through a removal duct attached to the nozzle) could be controlled as desired.
The nozzle was positioned close to the first and second support cylinders in a manner similar to the position of the nozzle 400 in figure 9. The first diverging surface of the nozzle was at a distance estimated to be approximately 1.5 to 2 mm from the surface of the nozzle.
- 38/42 first support cylinder, along an arc that extends approximately 128 degrees circumferentially around the first support cylinder. The second diverging surface of the nozzle was at a distance estimated to be approximately 1.5 to 2 mm from the surface of the second support cylinder, along an arc that extends approximately 28 degrees circumferentially around the second support cylinder. The protruding projection was centered on the contact line (the closest point of contact between the surfaces of the two cylinders), again analogous to the configuration shown in figure 9.
The temperature of the heated air supply was measured at 198ºC (390ºF), using two thermocouples and associated physical components. The volumetric flow rate of the heated air and the captured air was determined using a hot wire anemometer and associated physical components. The volumetric flow of heated air was approximately 1.0 cubic meter per minute. With the total area of the air distribution outlets being approximately equal to 54cm ”, and with the perforated metal screen comprising an open area percentage of approximately 28, the linear speed of the heated air on the working face of the outlets was estimated to be approximately equal to 11 meters per second. The return supply volume was approximately 1.14 cubic meters per minute, corresponding, therefore, to the capture of ambient air at a volumetric flow rate of approximately 14% of that of the impacted captured air.
The apparatus and methods described above were used to orient the elongated strip substrates and the non-woven mat in an arcuate path along the surface of the first and second support cylinders respectively, during which they passed narrowly through the first and the second divergent surfaces (respectively) of the nozzle, to be impacted with heated air with local capture of impacted air. Then, the substrates and the non-woven mat entered the contact line between the two support cylinders where the first substrate surfaces and a first support surface were brought into contact. The contact line between the two support cylinders was set at a low pressure, the pressure being estimated to be 9 Ni per linear centimeter (or approximately 5 pli (pounds per linear inch)). The linear speed of the two substrates and the non-woven blanket was adjusted to nominal 70 meters per minute.
After being placed in contact with each other, the substrates and the non-woven blanket circumferentially followed the surface of the second support cylinder along an arc of approximately 180 degrees before being removed from contact with the support cylinder.
This process resulted in the connection of two parallel strips of the substrate to the first surface of the nonwoven blanket, with a strip of the first surface of the nonwoven blanket.
The 39/42 fabric being exposed between the edges close to the substrate strips, and with the strips of the first surface of the non-woven blanket exposed beyond the edges away from the strips (analogous to the arrangement shown in figure 7). Upon inspection, it was found that the bond between the substrate strips and the non-woven mat was excellent, and that it was difficult or impossible to remove the substrate from the non-woven mat without significantly damaging or destroying one or both.
Notably, the bonded area extended completely along the contact area between the substrate and the non-woven blanket, including the edges of the substrate.
It was also noted that the second surface of the non-woven mat (the surface opposite the surface to which the substrate was bonded) in areas where the substrate was bonded was not significantly different from areas without the substrate.
That is, the bonding process did not appear to have significantly changed the thickness, density, or appearance of the nonwoven blanket.
It was also noted that the bonding process did not appear to affect or alter the protruding male fastening elements.
That is, no damage or physical deformation of the elements was observed.
Qualitatively, there was no difference in the thickness of the fibrous mat as a result of having been subjected to the bonding process.
Qualitatively, no differences were observed in the engagement performance of the fastening elements to the fibrous materials as a result of having been subjected to the bonding process.
Upon thorough inspection, it was observed that the non-woven blanket and the substrate were surface connected together, as described in the present invention.
Example 2 A composite non-woven blanket was obtained from 3M under the trade name EBL Bright (of the general type described in US patent 5616394), which comprised approximately 35 gsm of prolylene fiber (4 denier) connected in loops protruding protruding to a 35 gsm polypropylene support.
The strips of the substrate material of Example 1 were bonded to the fiber side of the non-woven blanket, using substantially the same conditions for Example 1. Again, excellent results were obtained, with excellent surface bonding along of the entire contact area between the non-woven mat and the substrate, and without apparent damage or densification of the non-woven mat and without apparent damage or deformation to the male fasteners.
Example Set 3 A non-woven blanket of continuous spinning-produced by block extrusion with high-speed (meltblown) hot air passage (50 gsm) continuous spinning (SMS) was obtained along with PGI Nonwovens, Charlotte, NC, USA, under the trade name LCO6O0ARWM.
Several blanket widths were used, usually in the 10 cm range.
A 40/42 oc substrate was obtained from 3M Company, St. Paul, MN, USA as described in Example
1. The substrate was obtained as an elongated strip 20 mm wide. A blanket handling device with a rolling contact line was established. The device had a first support cylinder made from metal and a second support cylinder made from wood, with the surface of the wooden cylinder covered by a silicone tape (obtained from Tesa, Hamburg Germany, under the designation commercial 04863). The support cylinders were placed in a vertical pile with the wooden cylinder on top of the metal cylinder, defining a contact line between them. The temperature of the support cylinders was not controlled. The non-woven blanket was oriented on the first metal support cylinder and the substrate was oriented on the second silicone-coated wooden support cylinder, with the protuberances facing the support cylinder. Auxiliary cylinders were placed close to the support cylinders to orient the substrate and the non-woven blanket in such a way that each one traversed an arc of approximately 130 degrees around its respective support cylinder.
The heated air was supplied by a heater available from Leister, from Kaegiswil, Switzerland, under the trade name LHS System 60L. The heated air was impacted against the substrates through a custom nozzle. The nozzle was produced from metal and had a feed inlet (opening system) at the rear of the nozzle that could be attached to a heated air supply duct. The nozzle body was produced from two laterally spaced and generally parallel side walls that extended horizontally along the long axis of the nozzle from the feed inlet at the rear of the nozzle to a tip at the front of the nozzle (closest to the tip). The side walls were substantially identical in shape; each having upper and lower edges with a defined sidewall height between them at any given location along the long axis of the nozzle. Along the distance from the rear of the nozzle to a location approximately halfway between the front and the rear of the nozzle, the upper and lower edges of each side wall diverged in such a way that the “height of the side wall was increased to a maximum level. Along the distance from this location (maximum side wall height) to the front of the nozzle, the side wall height decreased as the upper and lower edges of the side walls followed a smoothly arched converging path to meet each other. a point that defined the front of the nozzle. The arched shape of the upper and lower edges of the side walls was made to adapt generally to the curvature of the wooden support cylinder and the metal support cylinder, respectively. Therefore, the mouthpiece comprised an upper anterior face and a lower anterior 41/42 face, with the faces in a divergent relationship with the front end of the mouthpiece comprising a protruding protrusion.
On the upper and lower front faces of the nozzle, the side spacing between the side walls was approximately 20 mm. The inside of the nozzle was divided by metal partitions in order to provide six rectangular air distribution outlets each provided by an air distribution channel (with all channels being supplied with heated air from the same supply inlet on the back) back of the nozzle). Each air distribution outlet was approximately 20 mm in side width, with the vertical height of the outlets varying from approximately 2.5 mm to 4.0 mm (since the customized focal length, there was some variability in dimensions). One of the air distribution outlets was the protruding tip at the front of the nozzle, and was oriented to distribute the heated air in a generally direct way towards the contact line established by the two support cylinders. The upper face of the nozzle had three air distribution vents, oriented to distribute heated air to the substrate as it passed through an arc of approximately 45 degrees around the upper support cylinder just before passing through the contact line. The bottom face of the nozzle had two air distribution vents, oriented to distribute the heated air over the nonwoven blanket as it passed through an approximately 45 degree arc around the lower support cylinder just before passing through contact line. The air distribution vents were opened without any perforated metal screens being present. Between the air distribution channels inside the nozzle there were dead spaces (through which the heated air did not pass). Holes have been provided in the side walls of the nozzle at these dead space locations to provide ventilation. The nozzle did not contain any air capture inlet and there was no provision for local removal of the impacted air. In several experiments using the device, the nozzle was positioned in such a way that the air distribution outlets on the upper face of the nozzle were estimated as being in the range of 3-4 mm from the face of the upper support cylinder, and in such a way that the air distribution outlets of the lower face of the nozzle were similarly estimated at 3-4mm from the face of the lower support cylinder . In these experiments, the heated air was provided at various volumetric flow rates. It was not possible to measure actual volumetric flow rates during the experiments, however, offline tests indicated that volumetric flow rates were in the range of several hundred liters per minute. In these experiments, the heated air was provided at various temperatures, in the range of approximately 500 degrees C to approximately 700 degrees C. In these experiments, the substrate and the non-woven blanket were oriented on their respective support cylinders, passed in front of the nozzle. , and the 42/42 in contact with each other, at various linear speeds over the range of 105-210 meters per minute. Under these general conditions, the non-woven mat and the substrate were able to be bonded together to provide a surface bonded laminate as described in the present invention, without apparent damage or densification of the non-woven mat and without apparent damage. or deformation of the male fastening elements. In these general conditions, it was found that, with the combination of substrates and nozzle used in these experiments, a more robust connection was obtained at higher temperatures and / or at lower linear speeds. However, the degree of bonding that is suitable may vary with the particular application for which the laminate is to be used.
The tests and test results described above are intended to be illustrative only, not predictive, and variations in test procedures can be expected to produce different results. All quantitative values in the Examples section are understood to be approximate, in view of the commonly known tolerances involved in the procedures used. The detailed description and examples presented above have been provided for the sake of clarity only. No unnecessary limitations should be inferred from them.
It will be apparent to those skilled in the art that the exemplary structures, features, details and specific configurations, among others, that are presented in the present invention can be modified and / or combined in numerous modalities. All these variations and combinations are considered by the inventor to be within the limits of the conceived invention. Therefore, the scope of the present invention should not be limited to the specific illustrative structures described here, but instead, by the structures described by the language of the claims, and the equivalents of those structures. To the extent that there is a conflict or discrepancy between this specification and the presentation in any document incorporated by reference here, this specification will have authority. This application relates to provisional US patent application serial number xxhox, xxx entitled BONDED SUBSTRATES AND METHODS FOR BONDING SUBSTRATES, Precedent No. 65871US002, filed on the same date hereof, which is hereby incorporated by reference, in its entirety .

权利要求:
Claims (9)
[1]
1. Apparatus for impacting fluid against at least a first surface of a first moving substrate and a first surface of a second moving substrate and locally removing the impacted fluid, CHARACTERIZED by the fact that it comprises: at least one first distribution outlet fluids; at least one fluid capture inlet that is locally positioned in relation to the first fluid distribution outlet; at least one second fluid delivery outlet; at least a second fluid capture inlet that is locally positioned in relation to the second fluid distribution outlet; and the at least one first fluid distribution outlet and at least one second fluid distribution outlet are in a divergent relationship.
[2]
2. Apparatus according to claim 1, CHARACTERIZED by the fact that it additionally comprises at least one first fluid distribution channel connected fluidly to at least one first fluid distribution outlet, at least a second fluid distribution channel fluids fluidly connected to at least a second fluid delivery outlet, at least a first fluid removal channel connected fluidly to at least a first fluid capture inlet, and at least a second fluid removal channel fluidly connected to at least a second fluid distribution outlet. O
[3]
3. Apparatus according to claim 1, CHARACTERIZED by the fact that: the first fluid distribution outlet comprises a circumferentially elongated arcuate shape * and the first fluid capture entrance comprises a circumferentially elongated arcuate shape that is congruent to that of the first fluid capture entry; and, the second fluid distribution outlet comprising a circumferentially elongated arcuate shape and the second fluid capture inlet comprising a circumferentially elongated arcuate shape that is congruent - to that second fluid capture inlet.
[4]
4. Apparatus according to claim 3, CHARACTERIZED by the fact that the first fluid delivery outlet is flanked laterally outward by a pair of first fluid capture inlets and the second fluid delivery outlet is “-“ Tanked laterally outward by a pair of second fluid capture inlets: 3s 5. Apparatus, according to claim 4, CHARACTERIZED by the fact that the first fluid capture inlets are congruent to the first outlet of
[5]
- 2/4 fluid distribution, and the second fluid capture inputs are congruent to the second fluid distribution output.
[6]
6. Apparatus according to claim 3, CHARACTERIZED by the fact that the apparatus comprises a pair of laterally spaced first fluid distribution outlets, with a pair of first fluid capture inlets flanking laterally the pair of first outlets fluid distribution and with an additional first fluid capture inlet sandwiched laterally between the pair of first fluid distribution outlets; and * the apparatus further comprising a laterally spaced pair of second fluid delivery outlets, with a pair of second fluid capture & inlets flanking outwards the pair of second fluid delivery outlets and with a second fluid inlet. additional fluid capture sandwiched laterally between the pair of second fluid distribution outlets.
[7]
7. Apparatus, according to claim 4, CHARACTERIZED by the fact that the fluid distribution outlets collectively comprise a perimeter and the fluid capture inlets are positioned and dimensioned in such a way that at least 70% of the collective external perimeter is limited by fluid capture inlets.
[8]
8. Apparatus according to claim 1, CHARACTERIZED by the fact that each of the fluid distribution outlets comprises a work face comprising a fluid-permeable sheet.
:.
[9]
9. Apparatus, according to claim 8, CHARACTERIZED by the fact that each fluid-permeable sheet comprises a discontinuous screen with through openings that provide the sheet with a percentage of open area between 20% and 80%.
10. Apparatus according to claim 8, CHARACTERIZED by the fact that the fluid-permeable sheet of each fluid distribution outlet is positioned at an acute angle with the general direction of the fluid flow along a distribution channel. fluids to which the fluid distribution outlet is fluidly connected
11. Method of impacting heated fluid against, and locally removing the impacted fluid, a first surface of a first substrate in motion and a first surface of a second substrate in motion, the method CHARACTERIZED by the fact - - that it comprises: IT A to provide at least one first fluid delivery outlet and at least one first fluid capture inlet that is locally positioned relative to the first fluid delivery outlet; providing at least a second fluid distribution outlet and at least a second fluid capture inlet that is locally positioned with respect to the second fluid distribution outlet; passing the first moving substrate through the first fluid distribution outlet and impacting the heated fluid from the first outlet against the first surface e. main of the first moving substrate; passing the second moving substrate through the second fluid distribution outlet and impacting the heated fluid from the second outlet against the first main surface of the second moving substrate; and, capture locally at least 6% of the total impacted fluid volumetric flow through the fluid capture ports and remove the locally captured fluid through the fluid removal channels that are fluidly connected to the fluid capture ports; and the first and second moving substrates are convergent substrates.
12. Method, according to claim 11, CHARACTERIZED by the fact that it comprises capturing at least 8% of the volumetric flow of fluid to impact locally.
13. Method, according to claim 11, CHARACTERIZED by the fact that = it comprises capturing locally and substantially all the volumetric flow of impacted fluid.
14. Method, according to claim 13, CHARACTERIZED by the fact that the ambient air from an atmosphere surrounding the moving substrates is captured by the fluid capture entrances and removed by the fluid removal channels, the flow being volume of captured ambient air is at least — about 2% of the volumetric flow of the impacted fluid captured locally.
15. Method according to claim 11, CHARACTERIZED by the fact that at least one first fluid distribution outlet and at least one first fluid capture inlet are each positioned less than Smm from the first surface of the first moving substrate and the at least a second fluid distribution outlet and at least a second capture inlet
. 4/4 of fluids are positioned less than 5mm from the first surface of the second moving substrate.
o 18 150 110 Ve an É
RC DRSEII NAT CEILZAAR 1217 123 122 + Fig. 1 nm »Og 7 121 Fig. 2 - 4 Fig. 3 117
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DS AA SS O SS ASS AS SS NO e and AE a a a E
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SAN NE ASS SNS SRA ANS SAS SANS ASS SO SS A O SS SS
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SO SA NS UCS SS SNS SSSSSSSS SSSSASSS SSS SS SSSSSANS ES SO SS ASS S / AQSSE SOS E A E 121
SS SNS ASA SS SS SS SENNA
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NA SA AAA í 1 Fig. 6 00 um x * 3/8 120 and roo ode, A fo oo cssel 123 Besos lo º o E eo o oo [202 E 2 09, 110 22924 122 psd 0º% º oe a Poº o lo 5º 0 º6º lo oo Poco d bo 0º 161 fes. ho sos 160 aoselo floors: Po oºd E º 05º, so91162 matos o º 5º o o PO o o º 5º [o o o o 0º o k o aº o Po d bo 0º | 93º oo and so is this:
FS ES | Er: Thread. 7 ig. 110 1 122 121 112 120 123 113 400 231 21
Ê AN
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410 411 Va 422 ”415 442 Lo 421 NR 442 112 À 110 NO 231 / SE DN 420 431 NS 121“ Ses 424 434 120 | N 433, 7
E VIGO AT 430 A O
S VO Nes (The WS “VV 17 Wee, 6/7 & [. XY 222 Fig. 9 | e 5/8 | 543 542 542: 500 543 H 3521 | sax PA ip | 525 540 | 520 À 524, 540 Sha MA nd 4/0548 so] 101 s4s 542 542 sas 500 525 540 520, 544 524, give the CD 101
2a 6/8 542 543 542 543 SJ
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EDNA AE hM Tato Ironman o - and so ”Es Fig. 10C
510 51 VA 101 N 100 Ne NO 201 PAN: season 544 SS to 105 520 CA SEX 206 524 6 pa 560 540: is it EK 550 "564 544:) KZ 543 '554 560' 200 VW bes - 205 535 | XY 222 Fig. 711 and 8/8
VA 642 672 672 642 '643 1,643 | ea 621 Ex 621 ses | gi 625 670 H625 'nom | 640 620 | 620 '624 6741 624 640 4a MIA lu IA, | a / 6 101 Fig. 12

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法律状态:
2020-10-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

---

2020-10-13| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-01-26| B11B| Dismissal acc. art. 36, par 1 of ipl - no reply within 90 days to fullfil the necessary requirements|

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2021-11-23| B350| Update of information on the portal [chapter 15.35 patent gazette]|

优先权:

---

申请号 | 申请日 | 专利标题

---

US28895909P| true| 2009-12-22|2009-12-22|

---

US61/288,959|2009-12-22|

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PCT/US2010/061237|WO2011087750A2|2009-12-22|2010-12-20|Apparatus and methods for impinging fluids on substrates|

---