CN101194065A - 液体不可渗透而水分蒸汽可透过的地毯垫 - Google Patents

液体不可渗透而水分蒸汽可透过的地毯垫 Download PDF

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CN101194065A
CN101194065A CNA2006800206953A CN200680020695A CN101194065A CN 101194065 A CN101194065 A CN 101194065A CN A2006800206953 A CNA2006800206953 A CN A2006800206953A CN 200680020695 A CN200680020695 A CN 200680020695A CN 101194065 A CN101194065 A CN 101194065A
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carpet
carpet cushion
barrier layer
water
cushion
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CN101194065B (zh
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阿伦·D·奥泰森
布雷德利·W·伊顿
特洛伊·K·伊丝塔
苏珊娜·M·纳尔逊
贾森·J·布滕申
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3M Innovative Properties Co
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/04—Carpet fasteners; Carpet-expanding devices ; Laying carpeting; Tools therefor
    • A47G27/0437—Laying carpeting, e.g. wall-to-wall carpeting
    • A47G27/0468—Underlays; Undercarpets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0089—Underlays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
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    • B32—LAYERED PRODUCTS
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability
    • B32B2307/581—Resistant to cut
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/7242—Non-permeable
    • B32B2307/7246—Water vapor barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/758—Odour absorbent
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2508—Coating or impregnation absorbs chemical material other than water
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T442/2525—Coating or impregnation functions biologically [e.g., insect repellent, antiseptic, insecticide, bactericide, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3325—Including a foamed layer or component

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明公开了一种地毯垫，其包括结合到底层的阻挡层，其中所述地毯垫显示了：至少0的静态拒水性等级，至少20厘米水的静水压头，和(在70℉和50％RH下的)至少1000的MVTR。

Description

液体不可渗透而水分蒸汽可透过的地毯垫
技术领域
本发明涉及用于地毯或小地毯(rug)下面的地毯垫。
背景技术
大多数居室地毯料被铺设在被称为地毯垫(有时称为护垫(pad)或垫料(padding))的垫底物(underlayment)之上。地毯垫比仅用地毯料提供额外的柔软度和舒适度，增加地板覆盖材料的隔热和隔音，并增加地毯料的耐久性和外观保持性。许多地毯制造商推荐在新的地毯垫上铺设新的地毯料。
许多当前的地毯垫由泡沫橡胶制得，该泡沫橡胶可以是“原始(prime)”泡沫(即，为基本连续片形式的新泡沫)，或者是“再粘合”泡沫(即，新的或循环的泡沫和/或泡沫橡胶，其被切碎成小尺寸，然后再粘结在一起以形成连续片)。所使用的其它材料包括各种纤维垫和幅材(web)。
地毯垫典型地具有上层，其给易碎垫料提供了机械稳定性和抗撕裂性。另外，该层提供了光滑的表面，以便于地毯的铺设。在一些构造中，该上表面为连续膜，其被设计以提供抗水分传递性。在许多(如果不是大多数)构造中，所述上层主要用作粘合装置，并在组装过程中，被刺穿或“烧穿”，以使其具有液体可渗透性。
通过有助于容纳垫料或地板上的溢出物，耐水地毯垫底物提供了一种更彻底地清洁地毯上溢出物的方法。如果不能从地毯下面除去溢出物，则溢出物将会允许霉、霉菌和细菌的生长。结果不仅可能劣化垫料和下面的地板如木材，而且这样的条件可导致产生臭味和过敏原。因为对于大的或已安装的地毯，在溢出之后，发现和防止渗漏物进入垫料是典型地不切实际的，所以在已安装的或满铺的(wall-to-wall)地毯料上的溢出物是特别隐蔽有害的。在阔幅地毯料上的溢出物常常在垫料或下面的地板上混成糊状(puddles)，其中不能通过清洁而除去该溢出物。然后，该溢出物加速霉、霉菌和臭气的产生。
美国专利5,601,910和5,763,040(Murphy)描述了用防护整理剂(repellent finish)化学处理垫底物，使其基本上对溢出物是不可渗透的。通过仔细选择防水整理剂和胶粘剂，将垫底物粘附到地毯的下面，形成对溢出物基本上不能透过的阻挡层。
已建议使用塑料片如聚乙烯和聚(乙烯/乙酸乙烯酯)来制造不渗水的地毯料，所述塑料片被层压到地毯的底侧。然而，这样的背衬是昂贵的，造成制造困难，并妨碍地毯所需的透气性(空气渗透性)。这样不能防止霉和霉菌的生长。
此外，如果不是不可能，则在实际使用时，应用地毯/衬垫使得衬垫上的阻挡层保持完全的不渗透性是困难的。在衬垫部分、紧固件如钉子、和由地毯铺设和该过程中通常使用的工具所导致的地毯损坏之间的接缝，是液体溢出物能渗透甚至如下衬垫的所有位置，所述衬垫通过用专门的“不可渗透的”阻挡层保护。在这些情况下，将要成为的(would-be)不可渗透的阻挡层变成了负担，因为它大大减少了从构造中除去或蒸发掉溢出液体的能力。
需要提供如下性能的理想组合的地毯垫：对于例如来自溢出物的液体渗透抵抗，和地毯清洁，以及有效的干燥性能。
发明概述
如果能够制备一种改进的阻挡材料，其提供与连续膜阻挡层相似的抗压力和静态润湿性，同时构造阻挡层，使得它是空气可透过的，从而不会将可能导致霉或霉菌的水分捕获在其下面，这将是有利的。本发明提供了一种优良的地毯垫，其具有液体不渗透性，同时保留了蒸汽透过性。
简言之，本发明的地毯垫包括结合到底层的纤维阻挡层。该阻挡层提供充分的抗液性，以保护下面的底层不会被溢出液体渗透。地毯垫显示了以往不可相比的气流渗透性，其增强了气流通过地毯垫，从而有利于液体的干燥，该液体可能已从溢出物渗透进入或穿过地毯垫。
本发明的地毯垫提供了惊人的性能组合，包括同时提供高的抗液体湿气渗透性(即，排斥性)和高的透气性。由于高排斥性，本发明的地毯垫提供了抗溢出物渗透性，同时其高透气性允许有效地干燥已渗透到地板的液体。因此，本发明的地毯垫对污染的细菌、霉和霉菌的生成和臭味形成具有增强的抵抗性。本发明的地毯垫特别良好地适用于居室型地毯料或小地毯。
发明详述
简言之，本发明的地毯垫包括结合到底层的纤维阻挡层，其中该地毯垫显示了：至少0、优选至少1、最优选至少2的静态拒水性等级(Static water repellency rating)，至少15、优选至少40、最优选至少50的耐水性(静水压头)，和至少1000、优选至少2000、最优选至少3000克/码2/24小时的MVTR(在70和50％RH)。典型地，本发明的地毯垫会具有至少15、优选至少30、最优选至少50ft3空气/分钟/ft2面积(CFM/ft2)的透气性。
本发明提供了地毯垫或垫底物，其包括：纤维阻挡层和底层的复合材料，所述纤维阻挡层具有相对的第一和第二平面，所述底层具有相对的第一和第二平面。将阻挡层结合到底层。如果需要，阻挡层、底层、或两者可基本上不含氟化物，例如常规的防护整理剂。
按照需要，本发明的地毯垫可以绕成卷状物形式，或以片形式处理。
术语“地毯垫”如位于Dalton Ga.的地毯协会(Carpet and RugInstitute)(CRI)所定义，是指放置于地毯下的任何种类的材料，当在上面行走时，其提供弹性、支撑并降低噪音(CRI 105“居室地毯铺设标准”)。
术语“垫料”或“护垫”被认为与“地毯垫”同义。
阻挡层
阻挡层包括纤维材料。可透气的液体不可渗透的垫底物的纤维基底组分为任何机织的或非织造的织物或幅材，优选为轻薄的非织造织物，其选自：聚酯、聚烯烃、聚酰胺、聚(对苯二甲酸丙二醇酯)合成纤维、天然纤维、双组分纤维、纤维素纤维、羊毛、棉、丙烯酸、黄麻、及其共聚物和共混物。术语“纤维素”是指由木材或其他植物制得的纤维状纤维素基产物。双组分纤维包括：由两种聚合物制成的纤维，聚合物纤维与天然纤维或合成纤维的共混物，以及天然纤维与合成纤维的共混物。合适的非织造材料包括：纺粘幅材、稀松布(scrim)、梳理的幅材(carded webs)、闪纺幅材(flashspun webs)，或由聚合物纤维共混物组成的非织造片。优选的非织造材料为纺粘的或纺粘-熔喷-纺粘的聚烯烃材料。
典型地，本发明地毯垫的阻挡层具有至少为0的静态拒水性和至少为15厘米水的静水压头。
目前已令人惊奇地发现，许多织物可作为阻挡层应用到底层，以提供理想的高水平的液体阻止性(liquid hold out)或不渗透性，同时得到具有所需高透气性的构造。
本发明地毯垫的阻挡层透过或排出水分蒸汽的性能极大地增强，这相对于当前可用的构造是显著和有价值的改进。当将地毯垫铺设到木质(木材、胶合板、碎料板)地板或垫底物上时，通常用钉子将它适当固定，所述钉子刺穿了阻挡层，并压紧引起凹陷的周围衬垫，在所述凹陷内可收集游离液体。高性能地毯垫使用说明书常常规定用某物如管带(duct tape)来密封接缝，但常常没有进行这样的操作或没有仔细进行这样的操作。这样，在通常的环境下，不论原始阻挡层如何具有不渗透性，液体溢出物都可能渗透衬垫。
在新的构造中，垫底物常常是潮湿的或仍含有来自制造的残留水分。由于渗漏或冷凝，混凝土地板常常是轻微潮湿的。不管是什么来源，捕获在地毯中或在其下面的水分会导致细菌、霉、霉菌的生长，或甚至会导致腐烂。提高通过垫料的气流和提高干燥速率，将会有助于减少水分所导致的诸多问题。通过垫料的高速气流也将通过常规蒸发或通过真空提取而用于提高被支撑的地毯料的干燥速率。由于这些原因，非织造阻挡层相对于大多数目前的地毯垫构造具有许多优点。
如果需要，阻挡层可以印有标识、说明、保证信息等。
如果需要，阻挡层可以进一步包括或已被处理以赋予所需的特性，例如材料，以进一步阻止或抑制霉、霉菌或细菌的生长，或者阻止或吸收臭味。
底层
底层为弹性支撑层，其给上覆的小地毯或地毯提供许多所需的缓冲效果。
地毯料需要实体基础，以增加舒适性和耐久性，减少噪音，并提供绝缘。市售的居室地毯垫料典型地为约3/8至5/8英寸厚。
在本发明中，底层可以由泡沫橡胶制得，该泡沫橡胶可为“原始”泡沫(即，基本连续片形式的新泡沫)，或者为“再粘合”泡沫(即，新的或循环的泡沫和/或泡沫橡胶，其被切碎成小尺寸，然后再粘结在一起，以形成连续片)。另外，底层可以由其他弹性材料如本领域已知的材料制得，例如，它可以由各种形式的橡胶和氨基甲酸乙酯、毛发和黄麻的毡制组合、和纤维构造。
衬垫泡沫薄片本身是机械易碎的，在铺设过程中易于损坏或撕裂。另外，泡沫倾向于为防滑表面，所以这会使地毯料铺设更加困难。本发明的优点之一是，阻挡层材料倾向于赋予地毯垫更强的抗拉强度和抗撕裂性，使其比单独的底层更易于处理。在一些情况下，需要将加固稀松布包含到地毯垫中，典型地包含到阻挡层和底层之间，以便赋予地毯垫改进的机械稳定性和性能。
本发明地毯垫的底层典型地为约3/8至5/8英寸厚，但如果需要，可以使用更薄或更厚的层。
如果需要，底层可进一步包括或已被处理以赋予所需的特性，例如材料，以阻止或抑制霉、霉菌或细菌的生长，或者阻止或吸收臭味。
结合
使阻挡层和底层结合到一起。这可以通过自粘附来实现，例如热层压、或使用任选的中间粘合材料，例如不连续的胶粘剂幅材，其可以为压敏的或以某种方式活化。合适的粘合材料可容易地无困难地由本领域技术人员挑选。粘合材料不应过度地妨碍地毯垫所需的蒸汽渗透性。因此，它典型地是不连续形式。
铺设
常规地，放置垫料，并连接到地板上，例如，对于木地板，沿周边约每隔8英寸(20cm)放置金属钉，以防止在铺设过程之中或之后垫料移动、弯曲或撕裂。
本发明的地毯垫可以以任何需要的构型制造、运输和使用，所述构型为例如席或片，绕成卷状物形式等
实施例
试验方法
静态拒水性试验
该试验测定基底对水基试验物(challenge)的抵抗性。用水和水/异丙醇(IPA)混合物对样品进行试验，其中IPA浓度以10％(wt.)的增量增加。为方便起见，所述溶液根据IPA浓度命名：100％水(0％IPA)为“0”，10％IPA为“1”，20％IPA为“2”，等等。
将分开的五滴试验流体轻轻放在地毯垫样品的阻挡层的上表面之上，间隔几厘米(cm)。在15秒钟后，如果60％的液滴(3)还未润湿阻挡层(即，基本上仍保持珠状)，则评定该样品对该流体的等级为“合格”。如果60％(或更多)的液滴已润湿阻挡层，则评定该样品对该流体的等级为“不合格”。用给予“合格”等级数的具有最高IPA浓度的流体的数字来表示静态拒水性的级别。如果阻挡层不能通过100％水的试验，则其被评为“不合格”或给予数字等级“-1”。该试验的更详细描述记录于3M拒水性试验II：水/醇滴下试验(Doc.#98-0212-0721-6)。
耐水性：静水压试验
根据AATCC 127-1995试验方法，使用来自Alfred Suter Co.，Inc.，Ramsey，New Jersey的压力试验器，测定静水压。在该试验中，安装地毯垫样品，使得阻挡层的上表面被水覆盖，其下表面在大气压下对空气开放。如果水在零压差时不能润湿通过，则逐渐增加样品上表面上的水压，直到使水通过样品，或直到压力提高到仪器的极限值。对于该方法和设备，由样品表面以上的水柱高度(以cm为单位测量)得到跨过样品的压差。静水压结果越高，则通过压力，例如有人行走穿过地毯的湿区域，使水透过样品的可能性越小。
模拟行走耐湿试验
行走试验的目的是模拟如下情况，其中由于未察觉或忽视，液体溢出物浸到地毯内，然后在仍为潮湿的情况下，该液体溢出物受到脚步压力。典型的居室地毯料由多孔的常常高度填充的胶乳背衬制得。地毯能够吸收大量的溢出液体。溢出液体也倾向于通过润湿(芯吸)在地毯和背衬中散开，从而使游离液体被迅速吸收到地毯结构中。例如，典型的8盎司玻璃杯的水溢出物，会很快散布到允许其被吸收的区域。地毯料吸收液体的能力因地毯和背衬构造而变化。对于用于该测试中的地毯，测定被倒在样品中心上的130克水，在约10分钟内被完全吸收，并且向外的芯吸相当均匀，以润湿直径为约12英寸的圆形区域。为了确保所用液体的量不超过样品吸收和分配它的能力，在每平方英尺地毯100克水的基础上进行该测试。当使用较小的样品时，所应用的水量在上述基础上进行调整。用于各个试验的样品尺寸为12英寸×10英寸(30.5cm×25.4cm)，且所应用的水量为83克。
将地毯垫样品称重，并放置在与衬垫尺寸和形状完全相同的所称量的地毯片下面，从而使阻挡层与地毯背衬接触。将水“溢出物”应用到所述地毯，并使其静置30分钟。然后，操作者踩踏样品，接着撤回，进行两次。为确保一致性，由同一操作者完成所有的行走测试。然后将地毯和衬垫样品再称重，以确定水的分配。典型地，通过静置蒸发，和通过转移到操作者鞋子，会损失少量的水。
非织造材料
在实施例中使用如下非织造材料作为阻挡层。
非织造物#1为1.0盎司/平方码(“osy”)聚丙烯纺粘-熔喷-纺粘(SMS)，来自BBA Fiberweb，Brentwood，Tennessee。
非织造物#2为1.4osy聚丙烯纺粘-熔喷-纺粘(T0505)，来自BBAFiberweb，Brentwood，Tennessee。
非织造物#3为85.5克/平方米(“gsm”)聚酯纺粘(TN 1663)，来自Precision Custom Coatings LLC，Totowa，New Jersey。
非织造物#4为85.5gsm聚丙烯纺粘(TN 1668)，来自PrecisionCustom Coatings LLC，Totowa，New Jersey。
非织造物#5为1.25osy聚丙烯纺粘-熔喷-纺粘(SMS)，(125MLPO09U)，来自BBA Fiberweb，Brentwood，Tennessee。
非织造物#6为1.8 osy聚丙烯纺粘-熔喷-纺粘(SMS)，来自BBAFiberweb，Brentwood，Tennessee。
实施例1-7
使用常规热辊压延(calendar)层压机，通过将非织造材料层压到具有热熔聚烯烃粘性非织造幅材(来自Spunfab，Ltd.，Cuyahoga Falls，Ohio)的标准的7/16英寸厚，8磅/立方英尺的再粘合泡沫片，从而制备原型地毯垫构造物。如上面的试验方法所述，测试这些样品的静态拒水性、耐水性和模拟行走耐湿性。在表1中给出了性能数据。
同样对市售的贴有商标的地毯垫样品(具有防潮层的Odor EaterTM地毯垫，和包含DuPontTM Hytrel透气防潮层为主要部分的StainmasterTM地毯垫)测试静态拒水性、耐水性和模拟行走抗湿性。Odor EaterTM样品为原始泡沫型地毯垫，而不是再粘合型地毯垫。阻挡层看起来是连续膜，其在制造过程中已经被刺穿或“烧穿”，使得最终构造看起来是液体不可渗透的表面，但相反是穿孔不均的，具有足够小以阻挡静态液滴的孔。StainmasterTM样品作为再粘合构造评估行走拒水性。该构造的阻挡层看起来是非织造物在连续膜上的组合。该表面部分的显微镜检验没有发现在Odor EaterTM构造中所观察到的任何空隙类型。这些构造的性能数据也在表1中给出。
以保留在地毯垫中的所用水的百分比记录性能(在各种情况下，每个数据为重复4至6次的平均值)。
表1
    实施例     非织造物类型   胶粘剂幅材重量(克/平方码)   静态拒水性   耐水性(cm)   干重(g)衬垫   湿重(g)衬垫   Δ(g)衬垫   ％保留(衬垫中的H2O)
    1     #1   0.25   2   19.7   110.8   112.1   1.3   1.6
    2     #1   0.45   2   19.6   117.8   118.7   0.9   1.1
    3     #4   0.45   2   24.2   111.2   111.9   0.7   0.8
    4     #3   0.45   2   23.8   115.7   116.7   1   1.2
    5     #2   0.25   2   43.7   92.8   93.7   0.9   1.1
    6     #2   0.45   2   76.2   98.3   99.3   1   1.2
    7     #2   0.45   2   83.   105.8   106.6   0.8   1.0
    Odor EaterTM(原始泡沫)   10   14.6   67.1   68.1   1   1.2
    StainmasterTM(再粘合泡沫)   4   23.9   104.3   104.7   0.4   0.5
上面所有的实施例显示了拒水性和耐水性的所需平衡。即使市售地毯垫显示了比由非织造阻挡层制成的实施例地毯垫更高的拒水性，但是在模拟行走耐湿性方面没有显著区别。
实施例8和9
根据实施例1～7制备实施例8和9，除了在地毯垫构造中用于阻挡层的非织造物分别是非织造物#5和非织造物#6。
水分蒸汽透过性
测定实施例5和Odor EaterTM和StainmasterTM商业地毯垫产品的水分蒸汽透过速率(MVTR)。根据ASTM E 96标准试验——水蒸汽透过性来测定MVTR(直立的杯)，但具有下面的修改。通过将包括泡沫和阻挡层的完整衬垫构造的圆形区打孔，制造用于测试的样品。用胶粘带遮蔽阻挡层，以便具有相同的有效表面积。继续用表面掩模来遮蔽开放的泡沫边缘，并连续置于贮水池中，以防止除了试验表面之外的任意点处的水分损失。在70恒温的室内，在约70％RH以及约50％RH下进行测试。使用风扇使空气在试验表面上机械对流。在24小时时段内间隔测定水分损失，发现其近似线性，但在最后3～4小时内有些变平。24小时时段内的水分蒸汽透过速率(克/平方码)记录在表2中。
表2
    样品     MVTR70，70％RH     MVTR70，50％RH
    实施例5     3150     5233
    Odor EaterTM(具有原始泡沫)     2236     3141
    StainmasterTM(具有再粘合泡沫)     1710     1827
与商业产品相比，具有非织造阻挡层的实施例5地毯垫构造显示了在从衬垫下和透过该衬垫除去水分方面的显著改进。
透气性
对于实施例5、8和9和对于Odor EaterTM和StainmasterTM商业地毯垫产品，得到透气性数据。测试了两种StainmasterTM地毯垫类型(再粘合泡沫和原始泡沫)。为了比较，还得到了关于仅有再粘合泡沫(即没有阻挡层)的数据。使用Frazier低压透气性仪器，根据ASTM方法D737-04和D 737-96的程序来测定透气性，除了用胶粘带遮蔽样品，使得气流仅出现通过在每个2.65英寸(6.73cm)直径的打孔样品中心内的1英寸(2.54cm)直径部分。在表3中给出了透气性数据。
表3
  样品     泡沫厚度(mm)     透气性(cfm/ft2)
  实施例8     11.9     160.4
  实施例5     11.9     66.4
  实施例9     11.9     43.2
  Odor EaterTM(具有原始泡沫)     11.1     12.0
  StainmasterTM(具有再粘合泡沫     11.9     2.2
  StainmasterTM(具有原始泡沫)     10.3     ＜1.0
  聚氨酯再粘合泡沫(没有阻挡层)     11.9     287.4
与商业产品相比，具有非织造物作为阻挡层的地毯垫构造显示了在气流透过地毯垫方面的显著优点。
地毯的液体提取
这些试验的目的是为了确定从地毯/聚氨酯泡沫构造中可提取的游离液体和结合液体的量，并确定优选的提取方法(真空对沾吸(blotting))。第一实验包括：从两个不同的地毯/聚氨酯泡沫构造物区域提取液体，所述区域被固定到胶合板。最初，各个12英寸×12英寸的构造物具有100克被施加到地毯表面的水，允许其吸收15分钟。15分钟后，将样品称重(计算蒸发量)，并用工业级别的真空以交变的方向进行9次抽真空。然后将样品再次称重。在表4中给出了数据(以克为单位)。
表4-从地毯表面的液体提取(以克为单位)
    样品     初始重量     最后重量     提取重量
    实施例8     1101.7     1038.8     62.9
    Odor EaterTM(具有原始泡沫)     1067.1     1012.3     54.8
    StainmasterTM(具有原始泡沫)     1086.6     1034.0     52.6
    聚氨酯再粘合泡沫(没有阻挡层)     1092.6     1019.5     73.1
另一组12英寸×12英寸(30.5cm×30.5cm)的构造物具有从未保护的下面施加到衬垫泡沫的100克水，使其吸收15分钟。接着，将样品称重，重新组装地毯/衬垫/底层地板构造物，将地毯表面抽真空(如上所述)。然后将样品再次称重。在表5中给出了数据(以克为单位)。
表5-通过地毯表面从聚氨酯泡沫提取液体，以克为单位
  样品     初始重量     最后重量     提取重量
  实施例8     1037.8     1000.7     37.1
  Odor EaterR地毯垫(具有原始泡沫)     1011.4     996.2     15.2
  StainmasterTM地毯垫(具有原始泡沫)     1059.3     1055.6     3.7
  聚氨酯再粘合泡沫(没有阻挡层)     1063.7     1015.6     48.1

Claims (8)

1.一种地毯垫，包括：a)具有第一和第二主要表面的纤维阻挡层，和b)具有第一和第二主要表面的底层，其中将所述阻挡层结合到所述底层的一个所述主要表面，且所述地毯垫显示了：至少0的静态拒水性等级，至少15cm水的耐水性(静水压头)，和在70和50％RH下的至少1000克/码2/24小时的MVTR。
2.如权利要求1所述的地毯垫，其中所述地毯垫显示了：至少1的静态拒水性等级，至少40cm水的耐水性(静水压头)，和在70和50％RH下的至少2000克/码2/24小时的MVTR。
3.如权利要求1所述的地毯垫，其中所述地毯垫显示了：至少2的静态拒水性等级，至少50cm水的耐水性(静水压头)，和在70和50％RH下的至少3000克/码2/24小时的MVTR。
4.如权利要求1所述的地毯垫，其中所述阻挡层基本上不含氟化物。
5.如权利要求1所述的地毯垫，其中所述地毯垫基本上不含氟化物。
6.如权利要求1所述的地毯垫，其中所述阻挡层包括一种或多种材料以阻止或抑制霉、霉菌或细菌的生长，或者阻止或吸收臭味。
7.如权利要求1所述的地毯垫，其中所述底层包括一种或多种材料以阻止或抑制霉、霉菌或细菌的生长，或者阻止或吸收臭味。
8.如权利要求1所述的地毯垫，其中所述地毯垫被绕成卷状物形式。
CN2006800206953A 2005-06-09 2006-06-08 液体不可渗透而水分蒸汽可透过的地毯垫 Expired - Fee Related CN101194065B (zh)

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PCT/US2006/022339 WO2006135695A2 (en) 2005-06-09 2006-06-08 Liquid impermeable and moisture vapor permeable carpet cushion

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US20060280902A1 (en) 2006-12-14
CN101194065B (zh) 2011-05-18
CA2610926A1 (en) 2006-12-21
CA2610926C (en) 2013-09-17
WO2006135695A2 (en) 2006-12-21
WO2006135695A3 (en) 2007-07-26
EP1907622A2 (en) 2008-04-09

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