Method for producing layered article

Patent metadata

Field	Value
Publication number	US-10828839-B2
Application number	US-201615763254-A
Country	US
Kind code	B2
Filing date	Sep 15, 2016
Priority date	Sep 29, 2015
Publication date	Nov 10, 2020
Grant date	Nov 10, 2020

Abstract

Provided is a method of producing a layered article by which a sufficient production speed can be achieved, and preferably, a variation in fusion strength can be suppressed and hence a variation in product quality can be reduced. The method of producing a layered article of the present invention includes fusing at least part of a single-layer body or a laminate including at least one layer including a non-woven fabric of fiber having a fiber diameter of 100 μm or less through ultrasonic welding.

First claim

The invention claimed is:

1. A method of producing a layered article, comprising fusing at least part of a single-layer body or a laminate including at least one layer including a non-woven fabric of fiber having a fiber diameter of 100 μm or less through ultrasonic welding,
wherein the ultrasonic welding is performed with a horn and a rotating anvil,
wherein the rotating anvil is heated, and
wherein a pressing force between the horn and the rotating anvil in the ultrasonic welding is from 100 N to 1,500 N.

2. The method of producing a layered article according to claim 1 , wherein the method comprises fusing at least part of a laminate including two or three layers each including the non-woven fabric of the fiber having a fiber diameter of 100 μm or less through the ultrasonic welding.

3. The method of producing a layered article according to claim 1 , wherein the ultrasonic welding comprises continuous ultrasonic welding.

4. The method of producing a layered article according to claim 1 , wherein a temperature of the heating is from 30° C. to 150° C.

5. The method of producing a layered article according to claim 4 , wherein the temperature of the heating is from 40° C. to 100° C.

6. The method of producing a layered article according to claim 5 , wherein the temperature of the heating is from 60° C. to 80° C.

7. The method of producing a layered article according to claim 1 , wherein a fluctuation in temperature of the heating is within ±20° C.

8. The method of producing a layered article according to claim 7 , wherein the fluctuation in temperature of the heating is within ±10° C.

9. The method of producing a layered article according to claim 8 , wherein the fluctuation in temperature of the heating is within ±5° C.

10. The method of producing a layered article according to claim 1 , wherein a surface of the rotating anvil has an embossed pattern.

11. The method of producing a layered article according to claim 10 , wherein the embossed pattern comprises a discontinuous embossed pattern.

12. The method of producing a layered article according to claim 1 , wherein a ratio of an area of a fused portion obtained by the fusing through the ultrasonic welding to an area of an entire surface of the layered article to be produced is 50% or less.

13. The method of producing a layered article according to claim 12 , wherein the ratio of the area of the fused portion is from 1% to 40%.

14. The method of producing a layered article according to claim 13 , wherein the ratio of the area of the fused portion is from 10% to 30%.

15. The method of producing a layered article according to claim 1 , wherein the fused portion obtained by the fusing includes a fused portion of pieces of the fiber.

16. The method of producing a layered article according to claim 1 , wherein a number of holes each having a diameter of 100 μm or more present in the fused portion obtained by the fusing is 10 holes/m 2 or less.

17. The method of producing a layered article according to claim 16 , wherein the number of holes each having a diameter of 100 82 m or more present in the fused portion is 5 holes/m 2 or less.

Assignees

• Nitto Denko Corp

Inventors

• Uchida Shou
• Ikishima Shinsuke
• Takeda Kohei
• Nakagawa Muneshige
• Kuwabara Ryuji
• Kuzuhara Ikuya

Classifications

• B29C66/929

  characterized by specific pressure, force, mechanical power or displacement values or ranges · CPC title

• B29K2105/0088

  Blends of polymers · CPC title

• B29C66/91431

  the temperature being kept constant over time · CPC title

• B29C66/21

  said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding · CPC title

• A44B18/0011

  Female or loop elements (A44B18/0007 takes precedence) · CPC title