CN101522406A - 制备包含单向排列聚合物条带的织物的方法 - Google Patents

制备包含单向排列聚合物条带的织物的方法 Download PDF

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CN101522406A
CN101522406A CNA2007800373607A CN200780037360A CN101522406A CN 101522406 A CN101522406 A CN 101522406A CN A2007800373607 A CNA2007800373607 A CN A2007800373607A CN 200780037360 A CN200780037360 A CN 200780037360A CN 101522406 A CN101522406 A CN 101522406A
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polymeric tapes
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CN101522406B (zh
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J·A·D·巴克尔
B·C·克兰兹
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Novameer BV
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Abstract

用于制备包含至少一层单向排列的聚合物条带的方法，其中条带包含至少一个核组分，该方法包括在织机中形成至少一个单向排列的聚合物条带层的步骤，其中聚合物条带用作经纱且绑扎线用作纬纱，或者其中聚合物条带用作纬纱而绑扎线用作经纱，之后使用压力或热合并至少一个单层，其特征在于绑扎纱线的熔融温度低于合并温度，聚合物条带核组分的熔融温度高于该合并温度。

Description

制备包含单向排列聚合物条带的织物的方法
本发明涉及用于制备包含单向排列的聚合物条带的织物以及用其制成的物品的方法。
由于聚合物材料中的扭曲变形，聚合物条带通常是波浪形的且处理，即聚合物条带的加工因此非常困难。此外条带丧失了最佳的性能。
EP1627719公开了一种多层聚乙烯材料以及由其制造的抗冲击物品。这种多层材料包含多个单向取向的聚乙烯条带的单层。这种单层相互之间成角度斜交。在第一个单层之上形成第二个单层之前，通过应用压力和热将第一个单层合并。将第二个单层的条带调整为与第一个单层成一个角度后，通过再次应用压力和热形成双层垫。可以通过合并至少两个上述获得的双层材料获得多层材料。
用于制备根据EP1627719的物品的方法要求合并每一层并且因此非常费时。
US5578370公开了一种用于加工聚合物条带的不同的方法。这一文件公开了例如通过编织加工制备的相互交叉的伸长元件制备的垫子。伸长元件可以由两面涂布有具有比中间层更低的软化温度范围的聚合物材料的聚合物膜制备。由此获得的复合材料膜切割以形成条带。然后用条带通过编织、针织或铺设纤维状网形成垫子。通过将垫子加热在它们的交叉点上融合条带而合并垫子。融合之前可以形成两个或多个垫子叠放以获得包含至少两个编织的或针织的垫子的产品。
US5578370中公开的方法没有要求每个层的合并，这是因为垫子在针织过程中形成。在合并之前可以形成两个或多个垫子的叠放。
但是这种编织方法导致不均匀的表面。由于纺织织物中经纱和纬纱的交替方式以及贯穿整个织物的纱线在一根纬线上面并且在下一根纬线下面的事实，US5578370公开的条带被迫为弯曲的，即波浪形状。这导致与整齐和平坦的放置(lie)的单向排列的条带相比、就防弹性能即冲击强度而言较弱的产品。
因此本发明的目的在于至少减少现有技术的缺点并且提供用于包含单向排列的聚合物条带的物的制备方法，所述条带允许有效制造这种织物并且保持或加强强度和冲击性能。
这一目的通过用于制备包含至少一层单向排列的聚合物条带的织物的方法实现，该条带包含至少一个核组分，所述方法包括在织机中形成至少一个单向排列的聚合物条带层的步骤，其中该聚合物条带用作经纱且绑扎线用作纬纱，或者聚合物条带用作纬纱而绑扎线用作经纱，之后使用压力和热合并至少一个单层，其特征在于绑扎纱线的熔融温度低于合并温度，聚合物条带核组分的熔融温度高于该合并温度。
这一方法产生了聚合物条带平整且整齐的非波浪形织物，由此提供最佳的强度以及均匀的表面而不需要在形成多层产物的情况中单独合并每一层。
在根据本发明的方法中，聚合物条带的核组分并没有熔化并且因此保持了其初始的性质。
如果聚合物条带仅仅包含核组分，它仅包含一种聚合物或聚合物的均匀混合物而没有相分离。仅包括核组分的聚合物条带可以是纺丝单丝。这里使用的单丝一词包括任何单独纺丝的单独丝线，例如通过熔融纺丝或凝胶纺丝。仅包含单独组分的条带还可以采用固态挤出(SSE)或由固体材料切片，之后通过后拉伸制成。仅包含核组分的条带还来自于切割的一层膜。
在织机中聚合物条带以并排关系、相邻条带基本相互邻接地在拉力下定位。
聚合物条带和绑扎线可以形成为平纹织物、绸缎织物、斜纹织物和类似物。
优选绑扎线的熔融温度至少比聚合物条带的熔融温度低5℃，条件是聚合物条带的熔融温度高于合并温度。更优选绑扎线的熔融温度比聚合物条带的熔融温度低至少10℃，最优选绑扎线的熔融温度比聚合物条带的熔融温度低至少20℃，条件是线的熔融温度低于合并温度并且聚合物条带的熔融温度高于合并温度。
绑扎线可以是单丝纱线或复丝纱线。绑扎线可以具有包括四边形横截面的横截面的形状，只要绑扎线的熔融温度低于合并温度且聚合物条带的熔融温度高于合并温度以至于仅有绑扎线熔融并且在合并过程中其自身分布从而充当了对于熔融温度高于合并温度的条带的粘合剂。由此除去绑扎线引起的纺织波浪形状。
纱线材料选自由聚乙烯、超高分子量聚乙烯、聚丙烯、聚酰胺、聚丁二烯对苯二甲酸酯和聚对苯二甲酸乙二醇酯、聚萘二羧乙二醇酸、聚乙烯醇、聚亚环己二烯硫化物、聚氨酯、乙烯乙酸乙烯酯，这些聚合物的共聚物和它们的混合物组成的组。
优选用于根据本发明的方法中的聚合物条带的抗张强度为至少200MPa。
聚合物条带的抗张强度根据ASTM D638测量。
优选条带具有至少400MPa的抗张强度，更优选聚合物条带具有至少800MPa的抗张强度。
取决于聚合物材料和拉伸比，聚合物条带可以表现出20GPa或更高的抗张强度。
用于本发明上下文中的条带一词意味着柔性的、基本均匀宽度和厚度的伸长元件，其可具有除了环形之外的任何形状。条带的宽度/高度比为至少2，优选为至少5且更优选为至少20。优选根据本发明方法的条带基本具有四边形横截面。
为了获得具有高抗张强度的织物，优选聚合物条带以至少1:5的拉伸比拉伸，更优选聚合物条带以至少1:15的拉伸比拉伸。特别优选1:50或更高的拉伸比。
聚合物条带还可以表现出壳核结构。例如，如果将单丝用作条带，通过壳与核材料一起熔融纺丝，壳可以应用于核材料。壳材料还可以在后面的步骤中在织机中定位之前应用于核材料，例如使用刮刀、通过喷雾、粉末涂刷或使条带穿过聚合物溶液、分散液或乳液以及类似的方法。壳材料与核材料的比值范围为0.5/99.5到50/50重量％。优选壳材料的熔融温度低于核材料的熔融温度。更优选壳材料的熔融温度与绑扎线的熔融温度相似。所述核材料与所述壳材料特别选自由聚乙烯、超高分子量聚乙烯、聚丙烯、聚酰胺、聚丁二烯对苯二甲酸酯和聚对苯二甲酸乙二醇酯、聚萘二羧乙二醇酸、聚乙烯醇、聚亚环己二烯硫化物、这些聚合物的共聚物以及它们的混合物组成的组。
此外，壳材料可以选自由乙烯丙烯酸烷基酯共聚物(EAA)、乙烯乙酸乙烯酯共聚物(EVA)、乙烯丙烯酸丁酯共聚物(EBA)、乙烯甲基丙烯酸酯共聚物(ethylenemethyl acrylate copolymer，EMA)、线型低密度聚乙烯(LLDPE)、高密度聚乙烯(HDPE)、低密度聚乙烯(LPDE)组成的组。还有可能使用聚异丁烯(PIB)或聚氨酯(PU)作为壳材料。这些聚合物可以是非常柔性的并且可以表现出高的伸长。壳材料可以包含列出的材料之一或列出的壳材料的混合物。
用于本发明方法中的聚合物条带还可以通过切割多层聚合物膜制备。聚合物膜即核聚合物的一个或两个表面可以用具有比核聚合物更低熔点的树脂涂刷或共挤出。
四边形条带是单丝，其可以优选1.5mm到10mm宽，20μm到1500μm厚。通过切割膜制得得四边形条带可以是2mm到300mm宽并且取决于层的数量1μm到1000μm厚，优选4μm到50μm厚。
在根据本发明的方法中可以在织机中形成至少两层单向排列的聚合物条带，其中聚合物条带用作经纱且绑扎线用作纬纱，或者聚合物条带用作纬纱而绑扎线用作经纱。至少两层单向排列的聚合物条带叠放在彼此上面，其中相邻层的聚合物条带成角度斜交且使用压力和热合并叠放的层。
优选层彼此大约垂直斜交。但是它们也可以叠放成不是90°的角度。
根据本发明的织物可以包含多于2层，例如3，4或高达25，甚至高达50或100层在织机中形成的单向排列的聚合物条带，其中聚合物条带用作经纱或纬纱，且绑扎线用作纬纱或经纱。
在根据本发明的方法中进一步优选在织机中形成第一层单向排列的聚合物条带，其中聚合物条带用作经纱且绑扎线用作纬纱，在织机中形成第二层，其中聚合物条带用作纬纱而绑扎线用作经纱，第一层和第二层以交替方式叠放，其中相邻层的聚合物条带成角度斜交，且使用压力和热合并叠放的层。在这种第一和第二层交替方式中可以叠放高达100层。
如果以这样的方法形成层，即在织机中形成第一层单向排列的聚合物条带，其中聚合物条带用作经纱且绑扎线用作纬纱，在织机中形成第二层，其中聚合物条带用作纬纱而绑扎线用作经纱，可以以连续的过程进行合并。如果第一和第二层在机器方向上简单叠放，第一层和第二层的聚合物条带已经斜交，因为在第一层中条带为在经纱方向上的织物，而在第二层中条带为在纬纱方向上的织物。
在另一个优选的实施方案中，使层在织物或层之间的夹心处的一侧或两侧与基质层连接。基质层可以是膜、平纹织物、无纺布或类似的形式。基质层由聚合物材料组成，其熔融温度低于织物的合并温度。基质层还可以用作增强材料。优选平纹织物或无纺布作为增强材料。
如果希望的话，除了这些还提供其它任何合适材料的其它保护层。
根据本发明的方法制备的织物可以包含在复合材料结构中。在根据本发明的方法中制备的织物也可以包含在软和硬防弹结构中。
在特殊的实施方案中，特别优选如果该防弹结构具有一层或多层抗冲击材料，其中抗冲击材料优选选自由金属、金属合金、玻璃、玄武岩纤维、玻璃纤维、陶瓷或其它防弹材料，如芳纶纤维或超高分子量聚乙烯纤维中的一种或多种材料组成的组。抗冲击材料的层可以提供在织物的一个或两个表面侧或织物单独层之间的夹心处。
防弹结构可以是墙壁、门、盘子、背心或背心嵌入物、军事应用例如战斗头盔、身体防护物、用于地面交通工具、飞机机身和飞机舱门或船只的装甲板。

Claims (7)

1.用于制备包含至少一个单向排列的聚合物条带的层的方法，其中该条带包含至少一个核组分，该方法包括在织机中形成至少一个单向排列的聚合物条带的层的步骤，其中聚合物条带用作经纱且绑扎线用作纬纱，或者聚合物条带用作纬纱而绑扎线用作经纱，之后使用压力或热合并该至少一个单层，其特征在于绑扎纱线的熔融温度低于合并温度，聚合物条带的核组分的熔融温度高于合并温度。
2.根据权利要求1的方法，其特征在于聚合物条带为单丝。
3.根据权利要求1的方法，其特征在于聚合物条带为壳的熔融温度低于核的熔融温度的壳核条带。
4.根据权利要求1到3中任一项的方法，其特征在于聚合物条带的抗张强度为至少200MPa。
5.根据权利要求1到4中任一项的方法，其特征在于在织机中形成至少两个单向排列的聚合物条带的层，其中聚合物条带用作经纱且绑扎线用作纬纱，或者聚合物条带用作纬纱而绑扎线用作经纱，该至少两个单向排列的聚合物条带层叠放在彼此上面，相邻的层的聚合物条带成角度斜交并且使用压力和热合并叠放的层。
6.根据权利要求1到4中任一项的方法，其特征在于在织机中形成单向排列的聚合物条带的第一层，其中聚合物条带用作经纱且绑扎线用作纬纱，并且在织机中形成第二层，其中聚合物条带用作纬纱且绑扎线用作经纱，第一和第二层以交替方式叠放在一起，其中相邻的层的聚合物条带成角度斜交并且使用压力和热合并叠放的层。
7.软或硬防弹结构，其包含根据权利要求1到4任一项的方法制备的织物。
CN2007800373607A 2006-10-05 2007-09-29 制备包含单向排列聚合物条带的织物的方法 Expired - Fee Related CN101522406B (zh)

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