CN101065529B - 具有隆脊和沟槽的增强非织造挡火织物及用它挡火的制品 - Google Patents

具有隆脊和沟槽的增强非织造挡火织物及用它挡火的制品 Download PDF

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CN101065529B
CN101065529B CN2005800401627A CN200580040162A CN101065529B CN 101065529 B CN101065529 B CN 101065529B CN 2005800401627 A CN2005800401627 A CN 2005800401627A CN 200580040162 A CN200580040162 A CN 200580040162A CN 101065529 B CN101065529 B CN 101065529B
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fabric
enhancing
supatex fabric
fiber
fibre
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CN101065529A (zh
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L·N·巴斯坎
H·H·福斯滕
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EIDP Inc
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EI Du Pont de Nemours and Co
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Abstract

本发明涉及一种用于制品挡火的具有隆脊和沟槽的薄的增强非织造织物以及包含此类织物的制品。当暴露于热和火焰时，该织物能增加厚度至其原厚度的至少1.5倍。该织物包含网眼粗孔织物，其具有被压缩在其上并被热塑性粘结剂保持在压缩状态的卷曲、耐热有机纤维，其上被赋予了隆脊和沟槽结构。当受到高温或火焰时，结构中的粘结剂软化，从而释放被约束的卷曲的纤维和任何隆脊和沟槽并容许织物的厚度增加。

Description

具有隆脊和沟槽的增强非织造挡火织物及用它挡火的制品
技术领域
本发明涉及一种由卷曲纤维的压缩纤网和增强粗孔织物(scrim)制成的具有隆脊和沟槽的薄的增强非织造织物。当暴露于热和火焰时该织物将膨胀，并可用作挡火床垫、带垫套的家具等，尤其是基本上由泡沫塑料构成的那些制品的成分。本发明还涉及一种包括此种织物的挡火制品。
背景技术
加州发起了管制和减少床垫和床垫组件(set)可燃性的运动，旨在减少家庭、饭店和机构火灾中的死亡率。具体地说，the Bureau ofHome Furnishings and Thermal Insulation of the Department ofConsumer Affairs of the State of California(加州消费者事务部的家具和热绝缘局)颁布的技术公报(Techinical Bulletin)603“家用床垫/弹簧床垫(box spring)组件的耐大面积明火能力的要求和试验程序”量化了床垫组件的可燃性指标。在许多情况下，床垫制造商想包括一个挡火层，但他们不想让那个附加层损害了它们床垫的现有美学形象。
既结实又薄的织物，例如，短纤维与薄的增强粗孔织物(scrimfabric)的组合在许多情况下可能是可心的，因为它们耐用并且也可能不太令人反感。技术上公知有各种各样方法将这些短纤维和将短纤维固定在适当位置的粗孔织物结合在一起。此种方法之一是水力缠结(hydro-entangling)，在各种出版物中亦称作水刺(hydrolacing)、水力喷网(spunlacing)和水喷射处理(water-jet treatments)，其中以高压水射流冲击短纤维并将它们压入粗孔织物中，从而将纤维和粗孔织物压实在一起。技术上公知的另一种结合短纤维与粗孔织物的方法是针刺。在这一方法中，带倒钩的针抓住短纤维并将它们压入到粗孔织物中，或到内纤维絮片(batting)中，从而将整个结构固定在一起。由这些方法制造的非织造片材使短纤维它们之间或短纤维与粗孔织物或以这两种方式机械地并结实地缠结在一起，从而限制了织物在受热或暴露于火焰时膨胀的能力。
技术上公知将短纤维与粗孔织物结合的另一种方法是借助粘合剂(adhesive)层压或加入粘结剂(binder)。在该方法中，采用粘结剂或粘合剂将各个层或单根纤维粘合或粘结在一起。例如，授予Erb的美国专利6,579,396和6,383,623公开一种密度非常低的隔热材料，它具有由可燃热塑性粘结剂粘结的非热塑性纤维。授予Yamaguchi等人的欧洲专利EP 622332公开一种耐热和阻燃缓冲结构，包含卷曲非弹性短纤维的蓬松非织造纤网的基质纤维，按辉光试验(glowingtest)方法测试表现出残余重量至少35％的卷曲阻燃纤维以及热塑性弹性纤维；其中在基质纤维与阻燃纤维以及热塑性纤维之间至少某些交叉点被熔合粘结。该Erb和Yamaguchi专利都采用粘结剂来维持这些厚织物的蓬松或厚度；就是说，非织造织物维持在蓬松和鼓胀形式以便它具有回弹性。
如果床垫是泡沫塑料床垫，将织物结合到床垫中的过程将变得更困难。在典型情况下，将要包覆床垫的织物缝合成套筒或口袋式结构；然后机械地压缩泡沫塑料床垫并把套筒结构滑套到床垫上。松开机械压缩，于是泡沫塑料床垫便充满包覆套筒。该方法要求，在安装到此种床垫上去或当泡沫塑料床垫充分伸展到其原来的形状的同时，套筒材料具有足够伸长或弹性使得它不会被撕破。
Hartgrove的美国专利申请出版物US 2003/0213546公开一种适合作床垫褥覆盖物的耐用、可伸长非织造织物，其中床垫褥覆盖物的裙部必须表现出伸长性以便伸展罩住与该覆盖物适配的床垫的厚度。该织物，类似于其原料的水力缠结的非织造织物，当受热或暴露于火焰时具有非常有限的膨胀能力，因为其纤维被机械地缠结着。
因此，需要的是一种增强的非织造织物，它能伸长以便于安装在泡沫塑料床垫上而不会撕破，并且在正常使用下轻而薄，但当受到高温或火焰时将膨胀。
发明内容
本发明涉及一种用于给制品挡火的增强非织造织物，以及利用该非织造织物挡火的制品，其中该织物包含具有第一面和第二面的网眼粗孔织物(open mesh scrim)，该第一面和第二面具有被压缩在其上的卷曲、耐热有机纤维，该纤维被热塑性粘结剂维持在压缩状态，该织物还具有隆脊和沟槽，其中当织物暴露于热或火焰时，织物能增加厚度到其原厚度的至少1.5倍。
附图说明
图1是本发明具有隆脊和沟槽的代表性增强非织造织物的数字照片拷贝。
图2是用于制造本发明增强非织造织物的代表性基础压缩片材的数字照片拷贝。
具体实施方式
本发明涉及给制品挡火的薄的增强非织造织物。当暴露于热或火焰时，该织物能增加厚度到其原厚度的至少1.5倍。该织物包含具有第一面和第二面的网眼粗孔织物，该第一面和第二面具有被压缩在其上并被热塑性粘结剂维持在压缩状态的卷曲耐热有机纤维。该非织造织物还具有隆脊和沟槽。优选的是，该隆脊和沟槽由干起绉(crepe)处理提供，就是说，材料经过起绉处理但未胶粘地粘合到表面。优选的是，当织物安装在泡沫塑料床垫上挡火时，织物处于张力之下，它将相当数量的隆脊和沟槽拉直。当织物受到高温或火焰作用时，结构中的粘结剂就软化，松开受约束的卷曲纤维和任何隆脊和沟槽，并让织物厚度急剧增加。此种增加在织物中造成空气袋，据信这将提高织物的热性能。
该织物，作为对高温或火焰的响应，能增加其厚度，因为卷曲耐热有机纤维在织物中处于压缩但不明显缠结的状态。以前研发的纤维-粗孔织物片材集中在保证片材内纤维与粗孔织物和/或与其它纤维的高度机械缠结上面。就典型而言，此种机械缠结是通过向构成片材的纤维和/或粗孔织物的蓬松纤网输入能量以便使纤网缠结和使片材致密实现的。当这样做时，片材的纤维被如此地缠结，以致它们当遇到热和火焰时不能自由移动。
本发明织物的纤维仅具有足以制造片材的缠结程度；就是说，纤维仅彼此缠结到形成一种可以与网眼粗孔织物重叠或结合形成轻纤网所需要的程度。没有额外能量赋予片材以便使纤维彼此或者与粗孔织物缠结。随后，该轻纤网层压到粗孔织物，通过加热和压缩该结合物，随后将该结合物冷却以固定其结构，同时卷曲纤维被压缩和被约束。通过以此方式压缩蓬松片材，于是当粘结剂材料软化时片材中的纤维便自由返回到以前的蓬松状态，类似于它们被压缩之前的状态。
具有本发明的隆脊和沟槽的增强织物，当暴露于高温或火焰时，厚度增加到其原厚度的至少1.5倍。当未张紧的具有隆脊和沟槽的织物经历高温或火焰时，据信在织物中发生至少两种作用。这两种作用可通过单独考虑而得到最好的理解，即，归因于用来制成最终增强织物的基础压缩片材在高温或火焰期间的第一作用；和归因于最终增强织物中的隆脊和沟槽在高温或火焰期间的第二作用。第一作用是基础压缩片材的膨胀，它增加压缩片材的厚度，并因此增加最终增强织物的厚度。第二作用是最终增强织物中的隆脊和沟槽的松弛或展平，它趋于减少厚度。第一作用或膨胀作用大于第二作用或展平作用，因此提供一种具有隆脊和沟槽的增强织物，当受到高温或火焰时，能增加其厚度到原厚度的至少1.5倍，优选到其原厚度的2倍。
基础压缩片材优选地具有0.025-0.24cm(0.010-0.10英寸)总厚度。此种织物还优选地具有20-170g/m2(0.6-5oz/yd2)的基重(basisweight)，其中粗孔织物成分优选占到3.4-34g/m2(0.1-1.0oz/yd2)，而纤网成分优选地介于17-136g/m2(0.5-4.0oz/yd2)。如果该基础压缩片材在起绉前经历高温或火焰，随着温度的升高，膨胀率和膨胀量将增加，并且超过压缩厚度25倍的厚度增加是可能的。据信，需要低至150℃的温度引发膨胀效应，并且据信从约225℃的温度开始，膨胀作用将立即进行。最大膨胀量发生在未起绉、压缩的片材直接受到火焰作用时，此时已见到片材膨胀为其原厚度的约29倍。当不具有隆脊或沟槽的此种基础压缩片材直接暴露于火焰时，织物厚度优选地增加其原厚度的至少5倍，优选10倍。
本发明具有隆脊和沟槽的增强非织造织物的基重优选地介于约24-170g/m2(0.7-5.0oz/yd2)。此种起绉的织物还优选具有约0.06-0.3cm(0.15-0.76英寸)的总厚度。本发明具有隆脊和沟槽、未张紧的增强织物的厚度，当暴露于高温或火焰时，其厚度能增加到其原厚度的至少1.5倍。优选的是，当暴露于高温或火焰时，织物的厚度能加倍。作为本发明具有隆脊和沟槽的织物作用的一个说明例子，原厚度1.9mm的织物的未张紧样品当暴露于150℃的温度时增加到原织物厚度的约1.3倍；当暴露于200℃的温度时，其厚度增加到原织物厚度的约1.5倍；当暴露于225℃的温度时，厚度增加到原织物厚度的约1.8倍；而当暴露于250℃的温度时，厚度增加到原织物厚度的几乎2.5倍。如同基础压缩片材一样，据信，需要150℃的温度来引发膨胀作用，还相信，在约225℃的温度开始，或当接触火焰时，膨胀作用将立即进行。
当增强织物在床垫上被拉长时，也就是，当织物处于张力之下时，据信，由于不规则褶裥的展平，织物的一些区域变平至其原厚度的约10-25％。因此据信，当增强织物被实际用于泡沫塑料床垫时，基于张紧的增强织物的厚度，膨胀效应一般增加两倍以上。
本发明具有隆脊和沟槽的增强非织造织物包含卷曲耐热有机纤维。此种卷曲纤维优选是短纤维，其切断长度介于0.4-2.5英寸(1-6.3cm)，优选0.75-2英寸(1.9-5.1cm)，并优选具有2-5个卷曲/厘米(5-12个卷曲/英寸)。所谓“耐热纤维”是指，当纤维在空气中以20℃/min的速率加热至500℃时，纤维优选地保持其纤维重量的90％。此种纤维一般是耐燃的，就是说，该纤维或由该纤维制造的织物具有这样的极限氧指数(LOI)，使得该纤维或织物将不支持空气中的火焰，优选的LOI范围为约26和更高。优选的纤维当暴露于火焰时不过分收缩，就是说，当暴露于火焰时纤维的长度将不显著缩短。含有当在空气中以20℃/min的速率加热至500℃时保持其纤维重量的90％的有机纤维的织物，当被冲击火焰灼烧时，往往具备有限量的裂纹和孔洞，这对于作为挡火层的织物性能很重要。
可用于本发明增强非织造挡火织物的耐热和稳定的纤维包括由对位-芳族聚酰胺、聚苯并吡咯(polybenzazole)、聚苯并咪唑或聚酰亚胺聚合物制造的纤维。优选的耐热纤维由芳族聚酰胺聚合物，尤其是对位-芳族聚酰胺聚合物制成。
这里所使用的术语“芳族聚酰胺”是指一种聚酰胺，其中至少85％的酰胺(-CONH-)键直接连接在两个芳环上。“对位-芳族聚酰胺”是指这两个环或基团沿分子链彼此对位取向。添加剂可与芳族聚酰胺一起使用。事实上，现已发现，最高多达10wt％的其它聚合物材料可与该芳族聚酰胺共混使用，或者可使用具有多达10％的其它二胺替代该芳族聚酰胺的二胺，或者多达10％的其它二酰氯替代该芳族聚酰胺的二酰氯。在本发明的实施中，优选的对位-芳族聚酰胺是聚对苯二甲酰对苯二胺。制造可用于本发明的对位-芳族聚酰胺纤维的方法在例如，美国专利3,869,430；3,869,429和3,767,756中进行了一般披露。此种芳族聚酰胺有机纤维以及这些纤维的各种不同形式可从杜邦公司(Wilmington，Delaware)以商品名
Figure G2005800401627D00061
纤维购得。
可用于本发明的市售供应的聚苯并吡咯纤维包括
Figure G2005800401627D00062
PBO-AS(聚-(对亚苯基-2，6-苯并双噁唑))纤维、
Figure G2005800401627D00063
PBO-HM(聚(对亚苯基-2，6-苯并双噁唑))纤维，由Toyobo，Japan购得。可用于本发明的市售供应聚苯并咪唑纤维包括纤维，由Celanese AcetateLLC供应。可用于本发明的市售供应聚酰亚胺纤维包括
Figure G2005800401627D00065
纤维，由LaPlace Chemical供应。
替代地，“耐热纤维”可包括，当以20℃/min的速率在空气中加热至700℃时，保持其纤维重量的至少10％的纤维素纤维。这些纤维据说将成焦。具有10％结合到纤维中的无机化合物的再生纤维素纤维是优选的纤维素纤维。此类纤维以及此类纤维的制造方法在美国专利3,565,749和英国专利1,064,271中进行了一般性披露。一种本发明优选的成焦再生纤维素纤维是这样的粘胶纤维，它包含具有硅酸铝位点的聚硅酸形式的水化二氧化硅。此种纤维及其制造方法在美国专利5,417,752和PCT专利申请WO 9217629中进行了一般性披露。含硅酸并具有约31(±3)％无机材料的粘胶纤维由Sateri Oy公司(芬兰)以商品名销售。
该耐热纤维可与其它纤维掺混，然而优选的是，其它纤维不妨碍织物发挥火焰阻挡层的能力。例如，最高50％的变性聚丙烯腈纤维(modacrylic fiber)可与耐热纤维掺混。变性聚丙烯腈纤维之所以有用是因为该纤维当燃烧时释放灭火的含卤素气体。所谓变性聚丙烯腈纤维指的是由包含丙烯腈的聚合物制成的丙烯酸合成纤维。优选的是，该聚合物是包含30-70wt％的丙烯腈和70-30wt％含卤素乙烯基单体的共聚物。含卤素乙烯基单体是至少一种选自，例如，氯乙烯、偏二氯乙烯、溴乙烯、偏二溴乙烯等的单体。可共聚的乙烯基单体的例子是丙烯酸、甲基丙烯酸、此类酸的盐或酯，丙烯酰胺、甲基丙烯酰胺、醋酸乙烯酯等。
本发明使用的优选的变性聚丙烯腈纤维是丙烯腈与偏二氯乙烯结合的共聚物，并且该共聚物可另外具有氧化锑(一种或多种)以改进阻燃性。此种有用的变性聚丙烯腈纤维包括但不限于，美国专利3,193,602中公开的纤维，具有2wt％三氧化二锑；美国专利3,748,302中公开的纤维，由各种氧化锑制得，其加入量至少是2wt％，优选不大于8wt％；以及美国专利5,208,105和5,506,042中公开的纤维，具有8-40wt％锑化合物。优选的变性聚丙烯腈纤维可由Kaneka公司(日本)购得，例如，他们的Protex C纤维，据说含有10-15wt％氧化锑；或其它具有较少氧化锑的纤维(等于或小于6wt％)；或者也可使用不含氧化锑的纤维。
该卷曲的有机纤维优选地借助30重量份粘结剂材料适当固定。优选的粘结剂材料是靠加热激活的粘结剂纤维与粘结剂粉末的组合。典型的粘结剂纤维由软化点低于纤维共混物中任何其它短纤维软化点的热塑性材料制成。皮/芯双组分纤维优选作为粘结剂纤维，尤其是具有聚酯均聚物芯和粘结剂材料(如通常可由Unitika公司(日本)购得，例如以商品名
Figure G2005800401627D00071
销售)的共聚酯的皮的双组分粘结剂纤维。有用类型的粘结剂纤维还可包括由聚酰胺制成的那些，例如，Griltex PA Biko BA 1408dpf，2-英寸切断长度尼龙粘结剂纤维；或由聚丙烯、聚乙烯或聚酯聚合物或共聚物制成的粘结剂纤维，这些纤维仅包含那种聚合物或共聚物，或者是呈并列或皮芯构型的双组分纤维。优选的是，粘结剂纤维以最高的增强非织造织物的20％的数量存在。粘结剂粉末优选以最高的增强非织造织物的30％的数量存在。优选的粘结剂粉末是热塑性粘结剂粉末如共聚酯GriltexEMS 6E粘结剂粉末或Gnlon SMS D 1260 Aft62聚酰胺(尼龙)粉末。
本发明增强非织造织物还包含网眼粗孔织物。此种粗孔织物的基重优选为3.4-34g/m2(0.1-1.0oz/yd2)，之所以被称作“网眼”粗孔织物是因为这些粗孔织物沿经向(warp direction)和纬向(fill direction)都仅有约0.8-6根(ends)/厘米(2-15根/英寸)。最优选的网眼粗孔织物的基重为6.8-24g/m2(0.2-0.7oz/yd2)并且沿经向和纬向优选具有1-4根/厘米(3-10根/英寸)。一般而言，该网眼粗孔织物是通过将两组具有粘合剂涂层的交叉捻合(cross plied)的聚酯连续长丝或连续长丝纱粘结在一起制成的。在某些粗孔织物中，任何一个方向，譬如纬向的纱线可由按要求在横向经纱的一侧或两侧配置的大量连续长丝组成。代表性网眼粗孔织物可由Saint-Gobain Technical Fabrics ofNiagara Falls，纽约，以商品名
Figure G2005800401627D00081
Scrim Fabrics购得。两种型号网眼粗孔织物尤其适合用于本发明的增强非织造织物中。
Figure G2005800401627D00083
产品号KPM4410/P3由78分特(70旦)连续聚酯长丝沿经向和纬向制成并沿两个方向都具有1.6根/厘米(4根/英寸)。它的基重是6.8g/m2(0.2oz/yd2)并且连续长丝具有使交叉捻合的长丝定位的热塑性涂层。还有，
Figure G2005800401627D00084
产品号PQRS4351/R17是由167分特(150旦)连续聚酯长丝沿经向和277分特(250旦)连续聚酯长丝纱沿纬向制成，每根纱(或线)具有3根长丝并沿经向间距为1.6根/厘米(4根/英寸)和沿纬向1.2根/厘米(3根/英寸)。纱线内的每一根长丝的单丝线密度是2旦(2.2分特)。它的基重是23.7g/m2(0.7oz/yd2)并且连续长丝具有使交叉捻合长丝定位的热塑性涂层。此类型粗孔织物提供充足强度，但对可燃性没有太多贡献。又据信当织物暴露于高温时，网眼还有助于在织物内形成开放式空气袋，因为由于该纤网的粘结点数目很少，网眼粗孔织物应约束更少的耐热性纤维。粗孔织物可包括热塑性或非热塑性长丝，并且可以是芳族聚酰胺、尼龙、玻璃或聚酯。如果粗孔织物是热塑性的，例如，聚酯，当非织造织物燃烧时，随着卷曲耐热纤维的膨胀，在燃烧区域内这种网眼基本上消失。
本发明织物具有粗的(coarse)隆脊和沟槽，就是说，这些隆脊和沟槽不是微观的，而是明显突出的，一般包含约5-25个隆脊/线英寸(lineal inch)。所形成的隆脊和沟槽可以是规则或者是不规则的，但优选是不规则形成的隆脊和沟槽。所谓不规则形成是指，当观看隆脊和沟槽的图案时，织物中的隆脊和沟槽彼此之间并非一模一样。一般而言，这些隆脊和沟槽不相同，因为织物的厚度或织物中纤维的取向存在局部变化；当由于织物的相连接的段呈圆柱状塌陷而形成隆脊或沟槽时，每一增量塌陷的程度略有不同，从而导致实际隆脊和沟槽的差异。结果是这样一种织物，它优选地不与织物的另一层嵌套，因为隆脊和沟槽没有对齐。
图1是一幅数字照片的拷贝，表现出本发明的增强非织造织物1，其具有不规则隆脊和沟槽2。不具有隆脊和沟槽的基础压缩片材3显示在图2中。增强粗孔织物4遍布压缩片材和本发明织物中。
该起绉的压缩增强非织造织物可例如采用包括以下步骤的方法制成：
a)形成包含卷曲耐热有机纤维和粘结剂纤维的第一和第二纤网，
b)令纤网与网眼粗孔织物接触，所述粗孔织物具有接触第一纤网的第一面并且该粗孔织物具有接触第二纤网的第二面，结果形成织物装配体，
c)在织物装配体上施涂粘结剂粉末，
d)加热织物装配体以激活粘结剂纤维和粘结剂粉末，
f)压缩织物装配体至压缩状态，
g)将压缩状态的织物装配体冷却，形成增强非织造织物，以及
h)在压缩织物中赋予隆脊和沟槽
该纤网可采用任何能造成低密度纤网的方法形成。例如，来自成包的纤维的一簇簇卷曲短纤维和粘结剂纤维可由诸如清棉机(picker)之类的装置开松。优选的是，这些纤维是线密度为约0.55-约110分特/丝(0.5-100旦/丝)，优选0.88-56分特/丝(0.8-50旦/丝)的短纤维，最优选线密度约1-33分特/丝(0.9-30旦/丝)。
经过开松处理的纤维混合物随后可采用任何可利用的方法掺混，例如，气流输送，以形成更均匀的混合物。替代地，纤维可先混合以形成均匀混合物，然后再在清棉机内进行纤维开松。纤维的共混物随后可采用诸如梳理机之类装置转变为纤网，然而，可使用其它的方法例如纤维的气流铺网。优选的是，该纤网将从梳理机出来直接使用，不经任何交叉铺网。然而，如果要求的话，可随后将纤网经输送带送往例如交叉铺网机，通过将单片纤网的以Z字形结构层铺在彼此之上而形成纤网来制成交叉铺置的结构。
随后，来自一或多台梳理机的纤网与网眼粗孔织物可一起被收集在输送带上。优选的是，粗孔织物插入到两个纤网之间从而形成2-纤网结构。如果需要的话，在该两个纤网的任何一个可配置另外的纤网。随后，在合并的纤网和粗孔织物上施涂约3.4-24g/m2(0.1-0.7oz/yd2)的优选量的粘结剂粉末。该合并的纤网、粘结剂粉末和粗孔织物随后被送过烘炉(oven)，其温度足以软化和激活粘结剂纤维和粉末，从而其得以将纤维粘合在一起。在烘炉的出口，片材优选地在两个钢辊筒之间进行压缩从而将各层压实成为内聚性织物。随后，该织物优选地在此种压缩状态中冷却。
隆脊和沟槽可由任何可利用的措施赋予到压缩织物中，但优选的是赋予一系列不规则隆脊和沟槽的起绉方法，并优选的是微起绉或干起绉方法和设备，例如，描述在国际专利申请WO2002/076723，Walton等人；美国专利3,260,778，授予Walton；美国专利2,624,245，授予Cluett；美国专利3,426,405，授予Walton；和美国专利4,090,385，授予Packard等文献中。织物微起绉所采用的设备可从Micrex公司(Walpole，MA 02081)获得。一般地，此设备抵住驱动辊压缩待起绉织物，驱动辊将纤网推向阻滞元件，例如，阻滞刀，其刀尖被保持在邻近驱动辊的位置。阻滞元件通过片材的反复圆柱状塌陷导致纤网粗粗地在它本身折叠，结果形成优选的隆脊和沟槽。在塌陷的片材上可施加热量以便进一步软化或激活粘结剂纤维和/或粘结剂粉末，在此它们与耐热纤维相接触。这可有助于提供隆脊和沟槽的某些稳定作用；然而，由于当沿垂直于隆脊和沟槽方向在织物平面内对片材施加张力时，耐热纤维在织物中占压倒性多数，故一部分隆脊和沟槽能得以拉平。该基础压缩片材在微起绉处理期间被机械地线压实约4-30％，优选8-25％，按每单位面积片材的重量增加计。
本发明的织物随后可被结合到制品如一件家具上，或者优选地，一个床垫和基座组件上。一种给床垫挡火的方法是用本发明织物完全包裹床垫芯(mattress core)的镶板(panel)和边缘(border)，并在接缝处将织物缝合从而包住整个床垫。这保证床垫将得到挡火保护，不论是镶板还是边缘暴露于火焰。然而，在优选的方法中，本发明织物首先被缝合成为套筒或口袋的结构，随后将这个结构滑套到已经经过压缩的泡沫塑料床垫上。一旦床垫在套筒内落位，便可从泡沫塑料床垫上解除压缩，然后把织物结构中的开口缝合，并且如果要求的话，可用该材料将泡沫塑料床垫完全包裹。优选的是，应这样规定织物结构的尺寸，使得当泡沫塑料床垫上的压缩解除以后，泡沫塑料床垫膨胀并对织物施加张力，至少部分地拉直和展平大量隆脊和沟槽。基座，例如，弹簧床垫，一般不必做完全挡火处理，而是通常仅要求在边缘处挡火，对于基座的顶面或镶板而言，挡火是任选的。然而，本发明增强织物根据需要可以用于基座边缘或镶板。
该增强非织造织物据信给不能通过2003年7月颁布的加州技术公报603(California Technical Bulletin 603)的制品提供足够挡火作用，以便使该制品通过2003年7月颁布的加州技术公报603，而不需要加入化学阻燃剂材料。该增强非织造织物可以任何使本来试验不合格的床垫通过试验的方式结合到制品中。
试验方法
热重量分析
本发明所使用的纤维当以规定的速率加热至高温时，保持其纤维重量的一部分。该纤维重量采用TA Instruments(Waters Corporation的分部)(Newark，Delaware)生产的型号2950的热重量分析仪(TGA)测定。该TGA给出样品随温度增加的失重扫描。采用TA UniversalAnalysis程序，失重百分数可在任何记录的温度测定。该程序曲线包括：样品在50℃平衡；温度以10或20℃/min从50缓坡爬升到1000℃；用空气作为气体，供气量10mL/min；和采用500微升陶瓷杯(PN 952018.910)样品容器。
试验程序如下。采用TA Systems 2900控制器的TGA屏幕给TGA编写程序。键入样品ID，并选择计划的20℃/min温度爬升程序。利用仪器的皮重函数称空样品杯的皮重。将纤维样品切断为长约1/16″(0.16cm)，并将样品疏松地装入样品盘。样品的重量应介于10-50mg的范围。TGA具有一个天平，因此不必预先确定精确的重量。样品不应位于该盘之外。将装满样品的盘加载到天平金属丝(balance wire)上，确认热电偶靠近盘的上边缘但没有触及它。将烤炉(furnace)提升到盘的上方，并开始TGA。一旦程序完成，TGA将自动落下烤炉，取出样品盘，并进入到冷却模式。随后，利用TASystems 2900 Universal Analysis程序进行分析并得到在整个温度范围内的失重百分数的TGA扫描。
厚度
在实施例1和2中，基础压缩片材和具有隆脊和沟槽的增强非织造织物的厚度测定都采用ASTM D1777-96选项1进行测定。在实施例3中厚度测定是采用ASTM D5736-95测定的。
伸长率
在实施例中，载荷下的伸长率是采用修改的ASTM D5034程序测定的，其中应变在固定载荷2磅/英寸时停止。随后，样品在那个伸长率下保持15min，随后将载荷减少到0，并测定永久变形。这一过程在实施例中被称作ASTM D5034(修改)。
关于实施例中的织物组成，所有份数和百分数都指重量而言，除非另行指出。
实施例1
按如下所述制备增强非织造织物。80重量份2.2dpf，2″切断长度、型号970
Figure G2005800401627D00121
牌短纤维和20重量份4dpf，2″切断长度、型号4080 Unitika粘结剂纤维随着从棉包(bale)进料到两台梳理机中而实现混合。来自两台梳理机的纤网被收集在输送带上从而生产出基重约132g/m2的纤网。将聚酯长丝纱的网眼粗孔织物插入到由前两台梳理机形成的两片纤网之间。该网眼粗孔织物是
Figure G2005800401627D00122
PQRS4351/R17粗孔织物。所得结构具有在网眼粗孔织物的一面上的一个梳理纤网和在网眼粗孔织物的另一面上的一个梳理纤网。
EMS Griltex 6E P82/029聚酯-型粘合剂粉末被施涂到合并的纤网与粗孔织物上，施涂量使总片材重量达约132g/m2。合并的纤网、粘结剂粉末和粗孔织物被输送过140℃(285°F)的烘炉，从而激活粘结剂纤维和粉末。在烘炉的出口，片材在两个钢辊筒之间以0″间隙进行压缩，从而将诸成分压实成为内聚性织物。随后让织物在该压实状态中冷却。
织物的最终组成是：大约58％
Figure G2005800401627D00123
纤维、15％粘结剂纤维、20％聚酯粗孔织物和7％粘结剂粉末。压缩织物的重量是132g/m2。织物的厚度为约22密耳，按照ASTM D1777-96选项1。织物在载荷下的伸长率是0.5％，在每英寸宽度加载重量2磅的条件下，根据ASTM D5034(修改)。15分钟后的永久变形为0.1％，根据ASTMD5034(修改)。
随后，织物利用
Figure G2005800401627D00124
Microcreper(由Micrex公司(WalpoleMA)销售)，在约25％压实率下操作，进行微卷曲或微起绉处理，这又提供一种具有约8.5个隆脊每线英寸的片材。该织物的重量增加了约18％，达到156g/m2，同时厚度增加约150％，至57密耳。该织物在载荷下的伸长率是21.8％，在每英寸宽度2磅载荷下。该织物在15min后的永久变形是16.6％。
永久变形是在重物被去除以后15min时测定的样品长度增加百分数。压实率是由于片材的微起绉，片材沿纵向的长度缩小百分率。
实施例2
增强非织造织物按照实施例1中那样制备，不同的是，将聚酯粘结剂纤维换成基本上等量的Griltex PA Biko BA 140 8dpf、2英寸切断长度、尼龙粘结剂纤维。
织物的最终组成：大约59％
Figure G2005800401627D00131
纤维、15％粘结剂纤维、19％聚酯粗孔织物和7％粘结剂粉末。压缩织物的重量是124g/m2。织物的厚度为约23密耳，按照ASTM D1777-96选项1。织物在载荷下的伸长率是0.6％，在每英寸加载重量2磅的条件下，根据ASTMD5034(修改)。15min后的永久变形是0.1％，根据ASTM D5034(修改)。
随后，织物按照以前那样微卷曲或微起绉，但采用约15％的压实率，这样又提供一种具有约12.4个隆脊每线英寸的片材。虽然该织物每线英寸(linear inch)具有较多的隆脊数，但是隆脊和沟槽的幅度较低。织物的重量增加约9％，至135g/m2，同时厚度增加约78％，至41密耳。该织物在载荷下的伸长率是14.95％，在每英寸宽度2磅载荷下。该织物在15min后的永久变形是6.7％。
实施例3
该实施例展示本发明增强织物的膨胀行为。类似于实施例1那样制备增强非织造织物。该织物的初始厚度是0.074英寸(1.9mm)。织物样品被置于在不同温度下工作的加热烘炉内，当肉眼发现样品开始膨胀时记录下时间。继续以肉眼监视样品，样品完全膨胀的时间随着温度而变化，其中在150℃试验的样品的基本上完全膨胀出现在约5min，而在250℃试验的样品则改变为约1.5min。让样品在烘炉内停留总共15min，并记录最终膨胀厚度。样品的最终膨胀厚度采用Measure-Matic仪器在0载荷下测定(ASTM D5736-95)，结果示于表中。
表
Figure G2005800401627D00141

Claims (20)

1.一种用于给制品挡火的增强非织造织物，包含具有第一面和第二面的网眼粗孔织物，该第一面和第二面具有被压缩在其上的卷曲、耐热有机纤维，该纤维被热塑性粘结剂维持在压缩状态，该增强非织造织物还具有隆脊和沟槽，其中当增强非织造织物暴露于热或火焰时，增强非织造织物能增加厚度到其原厚度的至少1.5倍。
2.权利要求1的增强非织造织物，其中当增强非织造织物暴露于热或火焰时增强非织造织物能使其厚度加倍。
3.权利要求1的增强非织造织物，其中通过热塑性粘结剂和热塑性网眼粗孔织物的结合使得纤维保持在压缩状态。
4.权利要求1的增强非织造织物，其中具有5-25个隆脊每线英寸的纤网。
5.权利要求1的增强非织造织物，其中网眼粗孔织物包含热塑性材料。
6.权利要求1的增强非织造织物，其中热塑性粘结剂是粘结剂纤维。
7.权利要求1的增强非织造织物，其中热塑性粘结剂包含粘结剂纤维和粘结剂粉末的组合。
8.权利要求1的增强非织造织物，其中热塑性粘结剂包含聚酯或尼龙聚合物或其混合物。
9.权利要求1的增强非织造织物，其中耐热有机纤维是对位-芳族聚酰胺纤维。
10.权利要求9的增强非织造织物，其中对位-芳族聚酰胺纤维是聚对苯二甲酰对苯二胺。
11.权利要求1的增强非织造织物，其中耐热有机纤维由选自聚苯并吡咯、聚苯并咪唑和聚酰亚胺聚合物的聚合物制成。
12.权利要求1的增强非织造织物，其中耐热有机纤维是，当在空气中以20℃/min的速率加热至700℃时保持其纤维重量的至少10％的纤维素纤维。
13.权利要求12的增强非织造织物，其中纤维素纤维是含具有硅酸铝位点的聚硅酸形式的水化二氧化硅的粘胶纤维。
14.权利要求1的增强非织造织物，其中耐热有机纤维与最高50wt％变性聚丙烯腈纤维进行掺混。
15.包含权利要求1的增强非织造织物的挡火制品。
16.包含权利要求9的增强非织造织物的挡火制品。
17.包含权利要求1的增强非织造织物的挡火床垫。
18.包含权利要求9的增强非织造织物的挡火床垫。
19.包含权利要求1的增强非织造织物的挡火带垫套的家具。
20.包含权利要求9的增强非织造织物的挡火带垫套的家具。
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EP1815053A1 (en) 2007-08-08
US20060111000A1 (en) 2006-05-25
KR20070086582A (ko) 2007-08-27
WO2006058002A1 (en) 2006-06-01
CN101065529A (zh) 2007-10-31
JP2008520851A (ja) 2008-06-19
CA2582968A1 (en) 2006-06-01
BRPI0516791A (pt) 2008-09-30
DE602005025524D1 (de) 2011-02-03
KR101246404B1 (ko) 2013-03-21
MX2007006079A (es) 2007-07-11

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