CN102741046B - 高镂空度的非纺织的薄片材料及其构造方法 - Google Patents

高镂空度的非纺织的薄片材料及其构造方法 Download PDF

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Publication number
CN102741046B
CN102741046B CN201180008398.8A CN201180008398A CN102741046B CN 102741046 B CN102741046 B CN 102741046B CN 201180008398 A CN201180008398 A CN 201180008398A CN 102741046 B CN102741046 B CN 102741046B
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Prior art keywords
base wad
cardboard
chemical mixture
thickness
wad
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CN201180008398.8A
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CN102741046A (zh
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里泰诗·马布巴尼
布赖恩·泰勒
斯蒂芬·P·扬奇克
艾瑞克·K·施陶德
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Federal Mogul Powertrain LLC
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Federal Mogul Powertrain LLC
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Priority claimed from US12/720,119 external-priority patent/US20100168286A1/en
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明提供一种非纺织的吸声的薄片材料及其构造方法，该材料包括亚洲纸板和基布层。该构造方法包括提供亚洲纸板，并将该纸板碾碎成既定尺寸的碎片。进一步地，将纸板的减小尺寸的碎片与热粘合的织物纤维和人造短纤维结合以形成基本上均匀的混合物，然后，由该混合物形成网状物。然后，热粘合该网状物的组成成分以生成所需厚度的基垫。进一步地，在维持所述基垫的初始生成厚度的同时，在所述基垫的至少一面上层压基布层。

Description

高镂空度的非纺织的薄片材料及其构造方法
相关申请的交叉引用
本申请要求于2010年2月9日提交的美国临时申请序列号No.61/302,707的权益，本申请是2010年3月9日提交的美国申请No.12/720,119的部分连续案(Continuation-In-Part Application CIP)，该美国申请No.12/720,119是2008年1月9日提交的美国申请No.11/971,484的分案申请，该美国申请No.11/971,484现在的授权号为No.7,744,143，美国申请No.12/720,119和美国授权专利No.7,744,143都要求于2007年1月10日提交的美国临时申请序列号No.60/884,368的权益和2007年1月11日提交的美国临时申请序列号No.60/884,534的权益，上述所有专利通过引用整体合并入此处。
技术领域
本发明大致涉及一种非纺织的薄片及其构造方法，更具体地涉及一种吸声的，隔热的和/或结构的薄片，该薄片至少部分由通常不适合于再加工的废弃材料成分构成，更具体地涉及一种包括亚洲纸板的混合物。
背景技术
为了降低与制造非纺织的织物和材料相关的成本，并且最小化对环境的消极的潜在影响，很多消费品都采用回收成分来构造。例如，美国的汽车制造商利用回收材料来构造非纺织的织物和材料，该织物和材料具有各种应用，包括吸音作用和/或绝缘材料。用于构造吸音汽车平板的某些再生或回收材料包括劣质的纤维，例如棉，聚酯，尼龙或者回收的织物纤维的混合。劣等的棉由原始的或者回收的织物碎片形成，该碎片被结合并缝合以形成非纺织的织物。由回收的标准纸板纸或纤维形成的另一个产品是Ecco纸，该产品在有限的基础上使用以用于吸油。该产品使用标准的纸板，且该产品不具有其他使其阻燃、抗霉或者排尘的添加物。
美国商业公司和消费品制造商（例如汽车组件制造商和原始设备制造商）收到大量的来自于各个亚洲国家（例如中国和韩国）的货物，该货物的包装是由低等级的“亚洲纸板”构造而成的箱子或包装箱。该亚洲纸板具有非常短、非常细小的纤维成分，该纤维成分来自于在先回收的松木纸板（pinecardboard），以及竹纤维和稻纤维。因此，通过造纸厂的工艺来回收亚洲纸板制成纸、纸板或者其他结构的平板产品的尝试都失败了。该失败的尝试可以归因于亚洲纸板的非常细小的成分，在纸/纸板的制造工艺中，该细小的成分冲过承载纸浆的筛网或者网丝。该亚洲纸板的冲掉的成分被随后通过回收工艺产生的废物流进入到环境中。再进一步地，除了前面提到的被冲掉之外，因为在工艺中的对细小纤维的固有的压实操作，亚洲纸板的细小成分给制造“高镂空度、低密度”的最终产品带来了额外的困难。因此，至少因为这些原因，亚洲纸板被认为是一种废物，因此该亚洲纸板或者被以相对高人工成本地从可回收的标准纸板中分拣出来并被送到垃圾堆（在分拣过程中，由于其相对脆弱的结构以及其浅褐色或绿色的外观，该亚洲纸板可以容易地从标准的纸板中区分开来），或者如果超过5%的亚洲纸板被混合在回收的整包纸板中时，整包纸板被废弃，这同样将对产品制造商和环境带来相对高的成本。
发明内容
根据本发明的一个方面，提供利用亚洲纸板构造非纺织的薄片材料的方法，其中，该薄片材料被用于形成结构的和/或吸声的和/或隔热的平板。该方法包括提供亚洲纸板，并将该纸板碾碎成既定的尺寸的碎片。进一步地，将该纸板的减小尺寸的碎片与热粘合的织物纤维和人造短纤维结合以形成基本上均匀的混合物，然后，由该混合物形成网状物。然后，热粘合该网状物的组成成分以生成所需的既定厚度的基垫（matt）。再进一步地，在维持所述基垫的初始生成厚度的同时，在所述基垫的至少一面上层压基布层。
根据本发明的另一方面，本方法包括在基垫的至少一个表面上涂覆一种化学混合物并维持基垫的初始生成厚度，该化学混合物包括阻燃剂、杀菌剂和粘合剂。然后，在所述基垫上层压基布层之前干燥和固化该基垫。
根据本发明的另一方面，本方法包括缠绕该基垫，并控制在缠绕工艺中施加到基垫上的张力以避免压实基垫的“所形成的厚度”。
根据本发明的又一方面，提供吸声的非纺织的薄片。该非纺织的薄片包括由亚洲纸板、热粘合织物纤维和人造短纤维热粘合在一起形成所需厚度的基垫。进一步地，或者不使用夹轮或者利用几乎没有压力的夹轮以将基布层连接至基垫的至少一面上，其中，该基垫保持或者基本保持其初始生成厚度。
根据本发明的另一方面，该吸声的非纺织的薄片包括化学混合物，该化学混合物包括阻燃剂、杀菌剂和粘合剂，该化学混合物通过一种保持网状物的厚度的方法被涂覆、干燥和固化到网状物的至少一个表面上。
因此，本发明在此提供一种非纺织的薄片（该薄片例如适合在吸声的、隔热的或结构的应用中使用）及其构造方法，该方法通过回收将至少部分的亚洲纸板构造成“高镂空度（high loft）”的非纺织的吸声的、隔热的或其他的结构平板，该平板在制造中保持其低密度的基垫，该平板可用于各种应用中，例如应用于汽车中。
附图说明
为了更清楚地说明本发明的这些和其他方面、特征及优点，以下结合当前优选的实施例和最佳实施方式、所附权利要求以及附图对本发明进行详细描述，其中：
图1是根据本发明的一个当前优选方面构造的非纺织的薄片的局部透视图；以及
图2是根据本发明的一个方面构造非纺织的薄片的工艺流程图。
具体实施方式
更具体地参考附图，图1示出了根据本发明的一个方面构造的高镂空的、绿色的非纺织的薄片10，该非纺织的薄片也可简单称为薄片材料或平板。该平板10可被用于多种应用中，例如作为汽车组件使用。该平板10被构造为具有“高镂空度”（即低密度）的基垫12，该基垫12提供良好的噪声阻尼或衰减性能，因此，尤其适合于作为隔音平板使用。进一步地，如果预期用在高温环境中，例如在排气系统附近或者在汽车发动机室内，该平板10可被构造为具有阻燃性。该平板10至少部分由亚洲纸板14、人造短纤维和热粘合纤维构造而成，例如示出为16的双组分纤维。进一步地，该平板10可使用化学混合物涂层18构造，该化学混合物包括阻燃剂、杀菌剂和粘合剂，该涂层被涂覆、干燥并固化至其至少一个外表面上。再进一步地，该平板10具有基布层20，该基布层20被连接至基垫12的至少一面上，其中，该基布层20或者通过几乎没有压力（little to no pressure）的夹轮连接或者根本不使用夹轮连接，从而保持或者基本保持基垫12的初始生成的厚度。因此，该成型的平板10提供一种带有基布层20的低密度结构，“高镂空度”，从而提供良好的噪音衰减性能。进一步地，由于平板10至少部分由使用后或者回收的亚洲纸板14构造而成，对环境有利，使得回收的亚洲纸板14没有被送往垃圾堆，被焚化或者被归类为废物。
根据被构造的平板10的所需的性能特性，不管是混有亚洲纸板还是100%由亚洲纸板提供，纸板的含量优选占网状物总重量的25-99wt%。该亚洲纸板14被认为是一种低级别的、非可回收的纸板，因为其是由下等的组成成分构造而成的，该组成成分例如为低质量的、非常短和细小的回收纤维，例如竹纤维，麻纤维，稻纤维和/或其他废弃料/废料。因此，不管是其本身还是被混合或者通过其他方式包含在回收的使用后的纸板载体中，亚洲纸板通常被认为是一种严重的非可回收的废品污染物。因此，如果亚洲纸板与标准的美国纸板或者其他高质量的纸板混合在一起，然后该整个的混合体或载体通常被认为是不可回收的废品。由于亚洲纸板的脆度和浅褐色、黄色或者绿色的外观，亚洲纸板可轻易地从高质量的美国纸板中区别开来。因此，亚洲纸板通常被从高质量的美国纸板中分离出来，然后被送往垃圾堆，焚烧或者丢弃。
回收亚洲纸板的难点来自于亚洲纸板的构造中所使用的下等纤维的组成成分，该纤维通常非常短而且由此非常脆弱。考虑到亚洲纸板中的相对细小的纤维尺寸和其他粉末成分，如果亚洲纸板与具有较长纤维的标准纸板一起通过已知的“湿”回收工艺进行处理，亚洲纸板的成分被冲过筛网并且被带入废物流中，而且，该亚洲纸板的成分通常塞住或者以其他方式损害回收设备。因此，根据本发明的一个方面，平板10的构造通过“干”成网工艺进行，从而在制造过程中允许利用下等的亚洲纸板和长度小于0.2mm的纤维（被称为“细小粉末（fines）”）。
该人造短纤维可由任何合适的织物纤维提供，该织物纤维不仅保持了低密度基垫的高度，而且重量轻并提供高水平的吸音作用，而且该热粘合的纤维可被提供为例如低温度熔融的聚合物材料，例如聚乙烯纤维，PET或尼龙，和/或热塑性的双组分纤维，该双组分纤维的外层（例如聚丙烯）被加热到其熔点以上时发生熔融。如图2中的流程图所示，用于构造平板10的工艺包括混合或混配被碾碎的亚洲纸板14、人造短纤维和热粘合纤维16以形成网状物。该成网工艺例如可以在Rando机器上进行，形成一均匀混合的纤维/纸基垫或网状物，其中纸板14的纤维被随意定向。
然后，在形成网状物之后，该网状物被加热，例如在炉内，被加热到合适的温度以熔化该热粘合纤维（例如双组分低熔融纤维的外部分的熔点可能大约在110-180℃），从而热粘合亚洲纸板14与人造短纤维和热粘合纤维16的混合物。因此，该网状物被形成为基垫12，其中，该基垫12维持所需的高镂空度、低密度和增高的厚度t。如果没有该增高的厚度，较低的音频就不可能被基垫12所吸收，通常汽车制造商会把该较低的音频作为处理目标。
然后，在形成基垫12并冷却基垫12后，该化学混合物18例如在喷涂工艺中被涂覆到基垫12的至少一面上，而且优选被涂覆到基垫12的整个外表面，该化学混合物包括耐热或阻燃剂（FR）涂层、杀菌剂和粘合剂中的至少一种，耐热或阻燃剂涂层例如硫酸铵、磷酸铵或硼酸，杀菌剂和粘合剂在此作为示例而非限制为可使用具有+41Tg的SBR。该化学混合物18的喷涂应用可以维持基垫12的厚度，从而保持其高镂空度、低密度及其噪音衰减性能。涂覆混合物18之后，该混合物18被干燥并固化到基垫12。
获得的被涂覆的非纺织的基垫12从而具有薄的非纺织的织物或不透水的薄膜层，此后被简单称为基布层20，该基布层20连接或者粘合至基垫的一面或者两面上。该基布层20通过合适的示出为22的耐热粘合剂粘合到基垫12的一面或者两面上。关键的是，当连接基布层20时，维持或者基本维持基垫12的厚度以保持基垫12的初始形成的高镂空度和低密度，从而提供平板10所需的噪音衰减性能。这可以通过不使用夹轮或者几乎没有压力的夹轮来实现。如果更高的压力被施加到夹轮上，就会压实基垫12的厚度t，从而使得其密度增大，厚度减小，从而消减其所欲实现的噪音衰减性能。所保持的较高厚度与基布层20一起共同作用以衰减低音频率。
最终，在构造好薄片10之后，该薄片10被使用特定的缠绕工艺进行储存，例如围绕一个滚筒缠绕，其中，该缠绕工艺允许网状物10保持其被制造时的厚度t。该缠绕工艺被控制为在薄片10上施加一个既定的最大的张力，优选基本上均匀的张力。因此，适当选择该张力以阻止基垫12的厚度t减小。
显然，根据上述教导，本发明的很多修改和变型都是可能的。因此，应该理解，在所附权利要求书的范围内，本发明可以与所描述的具体实施方式不同的方式实施。

Claims (8)

1.利用亚洲纸板构造非纺织的薄片的方法，包括：
提供亚洲纸板；
将该亚洲纸板碾碎成既定的减小尺寸的碎片；
将该减小尺寸的碎片与热粘合的织物纤维和人造短纤维结合以形成基本上均匀的混合物；
由该混合物形成网状物；
热粘合该网状物的组成成分以生成所需厚度的基垫；
在维持所述基垫的厚度的同时，在所述基垫的至少一个表面上涂覆一种化学混合物，该化学混合物包括阻燃剂、杀菌剂和粘合剂中的至少一种；
干燥和固化该化学混合物；以及
在维持所述基垫的厚度的同时，或者不使用夹轮或者利用几乎没有压力的夹轮以在所述基垫的涂覆有化学混合物的至少一面上层压一基布层。
2.如权利要求1所述的方法，其特征在于，进一步包括将所述化学混合物提供为包括阻燃剂、杀菌剂和粘合剂。
3.如权利要求1所述的方法，其特征在于，进一步包括利用喷涂工艺涂覆该化学混合物。
4.如权利要求1所述的方法，其特征在于，进一步包括将该化学混合物涂覆到基垫的与基布层相对的一面上。
5.如权利要求1所述的方法，其特征在于，进一步包括将所述基布层提供为不透水层。
6.如权利要求1所述的方法，其特征在于，进一步包括在缠绕工艺的过程中缠绕该基垫并维持基垫的厚度。
7.如权利要求6所述的方法，其特征在于，进一步包括在该缠绕工艺中控制施加到该基垫上的张力。
8.一种根据权利要求1-7中任一项所述的方法构造的非纺织的薄片，包括：
由亚洲纸板、热粘合的织物纤维和人造短纤维通过热粘合在一起形成的所需厚度的基垫；以及
连接至所述基垫的至少一面上的基布层，所述基垫基本保持其起始生成的厚度。
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