CN102803594A - 非织造片材、由其构成的板材及其构造方法 - Google Patents

非织造片材、由其构成的板材及其构造方法 Download PDF

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CN102803594A
CN102803594A CN2010800278591A CN201080027859A CN102803594A CN 102803594 A CN102803594 A CN 102803594A CN 2010800278591 A CN2010800278591 A CN 2010800278591A CN 201080027859 A CN201080027859 A CN 201080027859A CN 102803594 A CN102803594 A CN 102803594A
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sheet
net
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nonwoven sheet
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哈利·F·格拉德费尔特
克里斯托佛·A·福伊
戴维·布里格斯
艾瑞克·K·施陶德
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Federal Mogul Powertrain LLC
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
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Abstract

本发明提供一种非织造片材及其构造方法。所述非织造片材包括热粘合性纺织材料和用过的消费后材料。用过的消费后材料包括通常视为非可再利用废品的处于未清洗状态的非热塑性材料、热塑性材料、包括不同类型的塑料成分的塑料组合物、以及包含诸如灰尘、油、油脂等污染物的其它材料中的至少一种。用过的消费后材料与热粘合性纺织材料粘合以形成非织造片材和由所述非织造片材形成的板材。

Description

非织造片材、由其构成的板材及其构造方法
相关申请的交叉引用
本申请涉及于2009年6月24日提交的美国临时申请61/219,972的权益该申请的全部内容通过引用并入本文。
技术领域
本发明涉及非织造板材和用于制造板材的方法，并且更特别地涉及至少部分由通常不适合再处理的使用过的废料成分，尤其是包含非热塑性塑料和/或不同类型的塑料/热塑性塑料的混合物构成的吸音板材、隔热板材(thermalpanel)和/或结构板材。
背景技术
为了降低与制造非织造织物和非织造材料相关的成本并且使得对于环境的可能的负面影响最小化，许多消费品是利用再循环成分构成的。例如，美国的汽车制造商利用再循环材料来构造非织造织物以及用于各种用途的非织造材料，包括吸声和/或绝缘材料。一些用于构造吸声车辆板材的再利用或再循环材料包括织物软毛线，例如棉布、聚酯、尼龙、或再循环织物纤维的掺合物。软毛线是由被结合在一起并用针缝制以形成非织造织物的原生或再循环织物碎料制成的。用在有限的基础上用于吸收油的由再循环的标准硬纸板纸或纤维构成的另一种产品是Ecco纸。在构成Ecco纸的工艺中，利用干燥再循环技术将标准的硬纸板纤维分解，并且剩余的纤维与各种添加物结合。
另外，对聚丙烯(PP)或聚对苯二甲酸乙二醇酯(PET)碎屑进行再循环是公知的。为了对它们进行再循环，通常在离心工艺中清洗碎屑。仅在进行清洗之后才将碎屑熔化并且再处理为原始颗粒状形式。而且，尽管该工艺在对用过的碎屑的构成成分进行再循环时通常是有效的，但是在由经过再循环的、用过的碎屑形成有用的最终产品之前需要单独的清洁工艺，这必然将为工艺增加成本并且因此为最终的再循环产品增加成本。
然而，各种废产品的再循环仍然存在问题，各种废产品例如为一次性手套、围裙、空气过滤器、防护盖、PET管擦拭器、泡沫橡胶盖、碳化钽(tac)碎屑、凯芙拉(Kevlar)手套、Kevlar套筒、尼龙手套、棉布手套、涂料浆辊介质、运动衫、泡沫减震器盖、具有热塑性细丝的玻璃纤维，等等，包括具有多于单种类型的塑料材料或者由非热塑性材料构成的物品。因此，通常不对这些类型的物品进行再循环，无论是由于成本高的清洁工艺的需要和/或缺少在单一工艺中对多种类型的塑料进行再循环的能力。相应地，这些类型的产品仍然是“废品”，因此持续地送到垃圾处理场或进行焚化，从而对环境具有有害的影响。
发明概述
依照本发明的一个方案，提供非织造产品。所述非织造产品包括热粘合性纺织材料和用过的消费后材料(used post consumer material)。用过的消费后材料包括非热塑性材料、热塑性材料和具有包括多于一种类型的塑料材料的构成成分的材料中的至少一种。用过的消费后材料与热粘合性纺织材料粘合。
依照本发明的另一方案，所述非织造产品为车辆板材。
依照本发明的另一方案，所述非织造产品为结构构件。
依照本发明的又一方案，所述非织造产品被构造为完全可生物降解。
根据本发明的另一方案，提供一种方法，通过由于成本、熔化/粘合或污染问题置入垃圾处理场或焚化的通常不能够再利用的用过的纺织物或制造中使用的泡沫废品、其它基于制造纺织物的废品或其它可粉碎废品来构造非织造片材。所构成的非织造片材用于形成结构板材、吸音板材、隔热板材和车辆板材中的至少一种。所述方法包括提供未经清洗的消费后碎屑。所述方法包括提供消费后碎屑，所述消费后碎屑包括处于未清洗状态的非热塑性材料、热塑性材料、包括不同类型的塑料成分的塑料组合物以及含有诸如灰尘、油、油脂等污染物的其它材料中的至少一种。所述方法进一步包括将消费后碎屑粉碎成预定尺寸的块。然后，通过将粉碎的块与热粘合性(低熔点)纺织纤维结合来形成混合物，然后形成预定厚度的混合物的网。另外，通过加热网以将热粘合性材料与用过的材料的粉碎块粘合来形成片材。
依照本发明的另一方案，所述方法包括在炉窖中或者通过一个加热辊、多个加热辊或一系列加热辊来加热网。
依照本发明的另一方案，所述方法包括在加热之前针刺网。
依照本发明的另一方案，所述方法包括：在形成网之前，将具有低熔点纤维的一次性热塑性材料添加到用过的废弃材料的粉碎块中。
依照本发明的另一方案，所述方法包括将反射层加到网上。
依照本发明的另一方案，所述方法包括：在形成网之前和/或之后，使用抗菌涂层和阻燃涂层中的至少一种来处理用过的废弃材料。
依照本发明的另一方案，所述方法包括：在形成网之前将粘合剂和热粘合性(低熔点)纺织纤维添加到材料的粉碎块中以防止“喷粉”(dusting out)。
依照本发明的另一方案，所述方法包括：通过经由一个或多个冷却辊来冷却加热的网，控制加热网之后片材的闷顶(loft)、厚度和密度。
依照本发明的另一方案，所述方法包括：根据应用的要求，将制作的片材切割为任何期望的形状。
依照本发明的另一方案，所述方法包括：将填料纤维添加到粉碎的材料块和低熔点材料中，以根据需要改变最终制成的片材的最终物理特性。
依照本发明的另一方案，所述方法包括：通过控制与热粘合性(低熔点)纺织纤维混合的粉碎材料块的尺寸和重量百分比，赋予片材预定量的吸音特性。
因此，本文的发明通过提供非织造板材以及构造非织造板材的方法克服了上文讨论的限制，其中所述非织造板材例如为适用于吸音、隔热或结构应用的板材，通过将所选类型的非热塑性材料和/或具有多于单一类型的塑料成分的材料进行再循环并且将它们与热粘合性纺织材料结合使用来生成可用于各种应用(例如，汽车)的非织造吸音板材、隔热板材或其它结构板材来实现构造非织造板材的方法。
附图说明
当结合当前优选的实施方案和最佳实施方式的下面的详述、随附的权利要求和附图考虑时，本发明的这些的和其它的方案、特征和优点将变得更加易于理解，其中：
图1为具有依照本发明的一个当前优选的方面的由非织造片材构成的非织造板材的车辆的立体图；
图2和图3为依照本发明构造的非织造片材的放大剖视图，所述非织造片材中具有用过的碎料的粉碎块的不同尺寸和重量百分比；以及
图4为显示具有反射材料的外层的与图2类似的图。
发明详述
更加详细地参照附图，图1示出了依照本发明的一个方案由非织造片材11构成的多个板材10。非织造片材11至少部分被制作以形成板材10，该片材至少部分由未清洗的消费后物品构成。通过实施例的方式而不是为了限制，板材10可被加工以用于很多场合，诸如图1所示的汽车部件。除了能够提供可成形结构件之外，板材10可被制造为具有噪声阻尼或衰减特性，因此用作吸音板。此外，如果要用于高温环境中，板材10可被构造为具有阻燃特性，例如靠近排气系统或在车辆发动机室内。板材10由用过的、可再利用的材料12构成，包括非热塑性材料、热塑性材料、具有不同类型的塑料成分的塑料材料、其它制造纺织品的废品以及其它可粉碎废品中的至少一种，所有这些通常均不能够再利用并且通常由于成本、熔化/粘合或污染问题被置入垃圾处理场或进行焚化。材料12在板材10内与热粘合性纺织(低熔点)纤维14粘合，包括单组分纤维或双组分纤维。用过的废材料12优选地保持在它们的用过、未清洗状态下，从而使得处理成本最小化。此外，其它适合的粘合剂材料和/或填料纤维可与用过的材料12混合以便于形成板材10，这取决于最终的用途。另外，各种涂层16可在材料12粘合之前和/或之后施加到板材10的至少一个外表面上。通过至少部分地由消费后或以其它方式使用过的材料12构成板材10，有益于环境，避免了再利用的材料12被送到垃圾处理场或进行焚化。此外，制造商由于能够将之前被认为是“废品“的碎屑和物品组合成有用的、可销售的产品而受益。
用过的材料12可作为混合物来使用，所述混合物包括用过的非热塑性材料、热塑性材料、具有不同类型的塑料成分的塑料材料、其它制造纺织品的废品以及其它可粉碎废品中的至少一种。例如，依照本发明，可被制成片材11的一些用过的产品，截止到现在被视为不可利用的“废品”，包括但不限于手套(例如由涂有硅酮的聚酰胺纤维或聚酯(不仅为基于单一聚合物的材料)构成的那些手套)、围裙、空气过滤器和/或防护盖、PET管擦拭物、泡沫机械手盖、tac碎屑、Kevlar手套、Kevlar套筒、尼龙手套、棉布手套、颜料浆辊介质、运动衫和泡沫减震器，以上作为例子但不限于此。通常在诸如汽车生产车间等制造设备中使用的前述物品或者未特别列出的其它废弃物品能够在未清洗的“污浊”状态下依照本发明制成板材10。因此，能够减除与清洁相关的成本。
可采用热粘合性纺织材料，这类材料例如作为低温熔点聚合材料(低熔点)，如，聚乙烯、PET或尼龙纤维。还可使用其它的低熔点聚合材料，例如热塑性双组分纤维，其诸如聚丙烯的外鞘当加热到其熔点以上时熔化。这些熔化的树脂随后熔融并且与存在的任何纺织纤维和用过的材料12的纤维的混合物以及与现有的任何其它粘合剂进行粘合。作为例子，与在大约250℃熔化的芯相比，PET低熔点纤维的外部的熔点可在近似110℃-180℃之间。另外，低熔点材料可以天然纤维质纤维提供，或者还可由用于构造片材11的用过的材料12内的一种或多种纤维来提供。本领域技术人员会理解，可以使用其它的涂层或填料和填料纤维来替代低熔点纤维以获得期望的结果，此外，热粘合性材料14可与粘合剂结合使用或者由粘合剂替代(例如，如果粘合剂用于硬化织物的感觉，可以使用更低熔点的纤维)。具有Tg+41的丁苯橡胶(SBR)为可使用的粘合剂的一个例子。此外，热粘合性纺织材料14可与诸如黄麻或洋麻等其它无机或有机纤维结合、和/或在热粘合性纺织材料和用过的材料12中的至少一个或两个上涂有耐热涂层或阻燃(FR)涂层(例如，硫酸铵、磷酸铵或硼酸)和/或涂有抗菌涂层(例如，Polyphase 678、Rocima 200、或UF-15)。
构造板材10的一种方法包括：如上文讨论的，例如通过再利用诸如上文所列出的用过的、脏污的物品来提供用过的材料12，然后无需清洗例如在切、撕碎、和/或研磨操作中将材料12粉碎为期望尺寸的块和/或干燥的纤维状态。根据所寻求的特性——诸如隔音或结构特性，可随具体应用场合选择性地改变粉碎块或类球物的尺寸和重量百分比含量。已经发现，通过改变碎块的尺寸和百分比含量，板材10的吸音特性改变。如果使用锤磨机来粉碎用过的物品，筛网可沿各种方向取向或呈现出各种形状，包括圆形、垂直或水平。如果经过研磨和/或锤磨的混合物与纺织纤维结合，该混合物则被抖松而便于与纺织纤维混合。
本发明的另一方案包括改变在板材10中使用的材料12的百分比以定制成品板材的吸音曲线。根据所使用的“填料”纤维，材料12可以增加吸音值或者可实际上降低成品板材的吸音值。通过改变在板材10中使用的材料12的重量百分比以及材料12的碎块的尺寸和/或纤维的尺寸，板材10可被设计为具有应用场合所要求的任何吸音曲线。
然后，材料12的经过锤磨的纤维和碎片与包括所述的低熔点纤维14的任何需要的再循环或原生纺织纤维、其它粘合剂材料或涂层进行混合。当融合，废弃的材料12的锤磨纤维和碎片与纺织纤维14的比例可改变以最佳适用于板材10的预期应用场合。低熔点纤维14可以具有诸如约5％的低百分比以使它们在成品板材10中的含量基本不易察觉。
然后，混合物经过非织造织网工艺，非织造织网工艺可在例如兰德(Rando)机器或其它更加通用的气流成网系统中进行。该织网工艺形成了均质或基本均质的混合纤维垫或网，材料12的纤维随机取向。然后，该网通过热粘合性炉窖以熔化低熔点纤维。或者，根据本发明的可选方案，在加热网之前，首先可将网送入针织机以进行针刺。无论怎样，可以通过使网进入或经过任何适当的炉窖或者通过将一个或多个加热辊来馈送网来执行加热工艺。所得网随后可在加热之后穿过冷却辊之间以控制其厚度和密度。如果针穿过网，耐撕的薄非织造层或者稀松布层可施于网的一面或两面上以防止在针上形成任何材料纤维或碎块12，因为针上材料12的形成是不期望的并且可导致破坏针。稀松布层还用作控制从网释放的灰尘的“网状物”。里梅(Reemay)织物为可用于该用途的稀松布的一个实例。织物的稀松布或保护层可另外为网增加强度并且便于织网工艺。网还可在加热网之前和/或之后覆有粘合剂，这样进一步将所有的纤维和材料粘合到位并且防止其形成灰尘(SBR、丙烯酸(Acrylic)或乳胶(Latex)粘合剂为可使用的一些实例)。阻燃剂也可添加到涂层中。在使用粘合剂时，优选地进行干燥和凝固。
然后，将网卷起或者切割成期望的长度。冲切机或类似的装置可用于将卷筒/片材分离为纤维产品的应用所规定的板材或部分。
所得非织造板材10可以具有附着或粘合到非织造纤维板材10的一面或两面或者夹在非织造纤维板材10的层之间的薄的非织造织物、稀松布和/或反射层16。稀松布和/或反射层可利用适当的耐热粘结剂、稀松布内的纤维的低熔点混合物进行粘合，或者可经由缝制接合进行贴附。例如为箔的反射层16增强了板材10的耐热特性。板材10和稀松布或反射层16可以具有层叠结构，从而根据需要提供多层板材10和交错的稀松布和/或反射层16。
依照本发明构成的非织造板材10适用于各种应用，包括汽车中的吸音板材和隔热板材。这样的应用更具体地包括汽车的成品内部板材和钢之间的吸音板，包括顶部内衬板、侧门板、车身和地毯之下。隔热应用包括例如通过添加反射层进行热屏蔽，诸如相邻的排气系统部件或发动机室内。其它应用可以包括热压缩零件或合成物。
根据上述教导可以对本发明进行多种改进和变型。因此，应当理解的是，可以除了特别描述的方式之外的其它方式来实践本发明，并且本发明的范围由最终通过的任何权利要求限定。

Claims (22)

1.一种构造非织造片材的方法，其特征在于该片材由用过的纺织材料、制造中使用的泡沫废物、其它基于制造纺织物的废品或其它可粉碎废品中的至少一种材料制成，所有这些材料通常均不能够再利用，并且由于成本、熔化/粘合或污染问题而通常置入垃圾处理场或进行焚化，所述片材用于形成结构板材、吸音板材、隔热板材和车辆板材中的至少一种，所述方法包括：
提供至少一种用过的、未清洗的非热塑性材料、未清洗的热塑性材料和具有多于一种类型的塑料成分的未清洗材料；
将所述未清洗的材料粉碎为尺寸减小的碎块；
将所述尺寸减小的碎块与热粘合性纺织材料结合以形成混合物；
在干燥非织造织网工艺中形成预定厚度的所述混合物的网；以及
加热所述网以将所述热粘合性材料与所述尺寸减小的块粘合，从而形成非织造片材。
2.如权利要求1所述的方法，其特征在于进一步包括：通过控制在所述网中混合的所述尺寸减小的碎块的尺寸和重量百分比，赋予成品片材预定量的吸音特性。
3.如权利要求1所述的方法，其特征在于进一步包括：在炉窖中或者通过一个加热辊、多个加热辊或一系列加热辊来加热所述网。
4.如权利要求1所述的方法，其特征在于进一步包括：在加热之前，用针对所述网进行针刺。
5.如权利要求1所述的方法，其特征在于进一步包括：在形成所述网之前，将具有低熔点纤维的一次性热塑性材料添加到所述粉碎材料块中。
6.如权利要求1所述的方法，其特征在于进一步包括：将外反射层附加到所述网上。
7.如权利要求6所述的方法，其特征在于进一步包括：设置箔形式的所述外反射层。
8.如权利要求1所述的方法，其特征在于进一步包括：在形成所述网之前，使用抗菌涂层和阻燃涂层中的至少一种来处理所述用过的材料。
9.如权利要求1所述的方法，其特征在于进一步包括：在形成所述网之后，使用抗菌涂层和阻燃涂层中的至少一种来处理所述用过的材料。
10.如权利要求1所述的方法，其特征在于进一步包括：在形成所述网之前，将粘合剂和热粘合性纺织纤维添加到所述粉碎材料块中。
11.如权利要求1所述的方法，其特征在于进一步包括：通过经由至少一个冷却辊来冷却加热的网，控制加热所述网后所述片材的闷顶、厚度和密度。
12.如权利要求1所述的方法，其特征在于进一步包括：在形成所述网之前，通过将填料纤维添加到所述粉碎材料块和所述热粘合性纺织材料中来改变成品片材的最终物理特性。
13.一种非织造片材，其特征在于包括：
热粘合性纺织材料；以及
用过的、未清洗的消费后粉碎材料，包括非热塑性材料、热塑性材料和包括多于一种类型的塑料材料的构成成分中的至少一种，所述用过的、未清洗的消费后材料与所述热粘合性纺织材料粘合。
14.如权利要求13所述的非织造片材，其特征在于其中所述片材形成为车辆板材。
15.如权利要求13所述的非织造片材，其特征在于其中所述片材形成为结构构件。
16.如权利要求13所述的非织造片材，其特征在于其中所述片材为完全可生物降解的。
17.如权利要求13所述的非织造片材，其特征在于，通过控制所述用过的、未清洗的消费后材料的尺寸和重量百分比，提供成品片材预定量的吸音特性。
18.如权利要求1所述的非织造片材，其其特征在于，用针对所述片材进行针刺。
19.如权利要求13所述的非织造片材，其特征在于进一步包括外反射层。
20.如权利要求19所述的非织造片材，其特征在于，所述外反射层为箔。
21.如权利要求13所述的非织造片材，其特征在于进一步包括包含在所述片材中的抗菌涂层和阻燃涂层中的至少一种。
22.如权利要求13所述的非织造片材，其特征在于进一步包括与所述粉碎材料块粘合的填料纤维。
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