CN104487242A - 粘合纤维垫的构建 - Google Patents

粘合纤维垫的构建 Download PDF

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Publication number
CN104487242A
CN104487242A CN201380039185.0A CN201380039185A CN104487242A CN 104487242 A CN104487242 A CN 104487242A CN 201380039185 A CN201380039185 A CN 201380039185A CN 104487242 A CN104487242 A CN 104487242A
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long filament
thermoplastic
coating
fiber mat
section
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CN104487242B (zh
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罗伯特·J·豪贝尔
杰拉尔德·D·波依兹顿
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Certainteed Gypsum Inc
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    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
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Abstract

本发明揭示一种用于构建纤维垫的系统和方法。根据本发明，用液化热塑性塑料预涂布连续长丝段。随后，在带上铺设所述预涂布的长丝以形成纤维垫。可以连续段铺设所述长丝或可将其切短成不连续段。在铺设所述长丝之后，将其加热以使热塑性塑料再液化并且促进交叉纤维之间的粘合。本发明进一步涉及一种用于将构建的纤维垫并入到复合建筑板中的系统和方法。

Description

粘合纤维垫的构建
技术领域
本发明涉及一种用于构建纤维垫的系统。本发明进一步涉及一种用于将粘合纤维垫并入到复合建筑板中的方法。
背景技术
背景技术含有构建纤维垫的方法的若干实例。西蒙斯(Simmons)等人的美国专利第5,565,049号中揭示了一个实例。西蒙斯揭示了一种由切短的纤维材料制造垫的方法。所述方法使用在一对辊上方延伸的拉长的、连续不断的传输带。一系列线轴在初始站将连续纤维股线传送到剪切站中。将切断的股线沉积到带上以形成宽松的纤维垫结构。随后将垫结构传输到喷嘴将精细水雾喷洒到垫结构上的喷洒站。随后将粘着剂粉末均匀涂覆在垫结构的顶表面上。粉末状粘着剂采用用粘着剂涂覆器计量的颗粒形式。在后续加热站提供对垫施加压力的上层带。加热站亦包括放置在垫结构上方和下方的加热元件。压力和热量使垫结构变平，并且使粘着剂塑化。接着，提供使垫温度下降到粘着剂的初始塑化温度以下的冷却站。这导致粘着剂再凝固并且将纤维粘合在一起。
里斯(Reese)等人的美国专利第5,051,122号中揭示了另一种制造纤维垫的方法。里斯揭示了一种由连续玻璃纤维股线制造垫的方法，其中使用经加热的压延辊和连续带来压紧垫。多个股线喂纱器横穿移动带孔传送机的表面，各喂纱器从供应源拉出至少一根连续股线，并且将其投到传送带表面上以形成宽松的纤维垫结构。电动树脂粒子分布在宽松垫上，随后在第二移动传送机或带与至少一个经加热的压延辊之间传递宽松垫。一个实施例使用水来湿润垫以便树脂材料较易于分布。当垫传递到第二传送带时，其在传送机表面与单独传动、旋转的经加热砑光辊之间被夹紧。当垫围绕辊圆周传递时，其通过带的拉力抵着辊被压紧。当带转动时，其将压紧的垫从砑光辊分离并且继续其路径。借助于罩盖排出来自砑光辊对垫的加热的蒸汽。
尽管以上参考文献中的每一篇都揭示了适用的构建方法，但所述参考文献亦受制于某些缺点。举例来说，每篇参考文献都涂覆粒子或颗粒形式的树脂或粘着剂。这种涂覆技术需要多个步骤，并且无法充分涂布下层纤维。因此，邻近纤维之间存在不充分的粘合。背景技术同样未能阐明用于构建与复合建筑板结合的纤维垫的方法。本发明的系统和方法旨在克服背景技术中的这些和其它缺点。
发明内容
本发明涉及用于构建纤维垫的系统和方法。本发明还涉及用于将纤维垫并入到复合建筑板中的系统和方法。
本发明的一个可能优势通过由用热塑性塑料预涂布的长丝段构建纤维垫来实现。
另一优势通过在将长丝段并入到纤维垫中之前用液化的热塑性塑料充分涂布连续长丝段来达成。
另一可能优势通过在已经将长丝铺设到成形台上之后加热长丝，借此使预涂料液化并且促进交叉长丝之间的粘合来实现。
另一潜在优势通过构建纤维垫并且随后将构建的垫并入到复合建筑板中来实现。
又一优势是构建不需要纸质表面薄片或背衬薄片而仍可并入到建筑板中的纤维垫。
本发明的各种实施例可能不具有这些优势、具有这些优势中的一些或全部。本发明的其它技术优势对于所属领域的一般技术人员应是显而易知的。
附图说明
为了更完整地理解本发明和其优点，现在结合附图参考以下描述，其中：
图1是根据本发明的生产工艺的侧视图。
图2是根据本发明的替代性生产工艺的侧视图。
图3是在将纤维并入到垫结构中之前预涂布单根纤维的装置的侧视图。
图4是用于在已经将长丝预涂布之后以及在并入到纤维垫中之前储存长丝的线轴的视图。
图5是说明预涂布以及单根长丝互连的纤维垫的特写视图。
图6是说明预涂布以及单根长丝互连的纤维垫的特写视图。
图7是说明预涂布以及单根长丝互连的纤维垫的特写视图。
具体实施方式
本发明涉及一种用于构建纤维垫的系统和方法。根据本发明，用液化热塑性塑料预涂布连续长丝段。随后，在带上铺设预涂布的长丝以形成纤维垫。可以连续段铺设所述长丝或可将其切短成不连续段。在铺设长丝之后，将其加热以使热塑性塑料再液化并且促进交叉纤维之间的粘合。本发明进一步涉及一种用于将构建的纤维垫并入到复合建筑板中的系统和方法。下文将更详细地描述本发明的各种特征以及其相互关联的方式。
图1说明优选的生产系统10，其包括可以由一系列成形台22组成的单个生产线20。所述线的初始部分24用于由连续长丝段26构建纤维粘合垫。如下文更详细地描述，在变成纤维垫28之前，用热塑性塑料预涂布这些长丝段26。随后，生产线的后面部分32将纤维粘合垫28并入到复合建筑板中。所述生产线的这一后面部分可并入与颁予豪伯(Hauber)且名称为“经玻璃强化的石膏板(Glass Reinforced Gypsum Board)”的共同拥有的美国专利第6,524,679号中所揭示的生产方法。出于所有目的，将'679专利的内容全部并入本文中。
图2是在许多方面与图1的生产线类似的替代性实施例。即，线24的初始部分用于形成纤维垫28，而后面部分将纤维垫28并入到复合建筑板中。然而，图2的生产线利用长丝切断器将连续长丝段切断成不连续段。随后，将不连续纤维段随机沉积在形成台上。值得注意的是，这两个实施例均以最初用热熔性热塑性塑料预涂布的连续长丝段26开始。
用热塑性塑料涂布长丝的系统
首先，以未涂布状态从多个相应长丝喂纱器分配多个单根长丝段26。或者，可直接从长丝生产工艺供应纤维。在优选实施例中，长丝26的直径在最小约1微米到最大约5,000微米的范围内。如本文所使用，术语“长丝”包括单丝和粘合在一起形成纱束的多根长丝。其进一步包括短纤复丝股线和编织复丝股线。所使用的长丝26的数目将取决于所构建的纤维垫28的大小和密度，并且本发明不限于长丝26的任何特定数目。然而，据设想，可利用2根到2000根的单根长丝26。从喂纱器分配长丝26之后，借助导辊将长丝导引到图3中所描述的涂布站34。在涂布站34，将未涂布的长丝段26各自浸没在热塑性塑料预涂料中。
在优选实施例中，用一定体积的液化热熔性热塑性塑料粘合剂涂布每根长丝。粘合剂可以是有机或无机粘合剂或其组合。目标在于提供将单根纤维固定在原地并且提供抗拉伸性和柔韧性的粘合剂。优选的热塑性塑料粘合剂包括单独或彼此组合使用的以下中的任一种：丙烯腈丁二烯苯乙烯(ABS)、赛璐珞(Celluloid)、乙酸纤维素、乙烯-丁基、丙烯酸酯、乙烯-丙烯酸甲酯、乙烯乙酸乙烯酯(EVA)、乙烯-丙烯酸-酸共聚物(EAA)；乙烯乙烯醇(EVAL)、氟塑料(PTFE，包括FEP、PFA、CTFE、ECTFE、ETFE)、离聚物、液晶聚合物(LCP)、聚缩醛(POM或缩醛)、聚丙烯酸酯(熔化和固化丙烯酸酯)、聚丙烯腈(PAN或丙烯腈)、聚酰胺(PA或耐纶(Nylon))、聚酰胺-酰亚胺(PAI)、聚芳基醚酮(PAEK或酮)、聚丁二烯(PBD)、聚丁烯(PB)、聚对苯二甲酸丁二酯(PBT)、聚对苯二甲酸丁二酯(PET)、聚对苯二甲酸环己烷二甲醇酯(PCT)、聚碳酸酯(PC)、聚酮(PK)、聚酯、聚乙烯(Polyethylene/Polythene/Polyethane)、聚醚嵌段酰胺(PEBA)、聚醚醚酮(PEEK)、聚醚酰亚胺(PEI)、聚醚砜(PES)、氯化聚乙烯(PEC)、聚酰亚胺(PI)、聚乳酸(PLA)、聚甲基戊烯(PMP)、聚苯醚(PPO)、聚苯硫醚(PPS)、聚邻苯二甲酰胺(PPA)、聚丙烯(PP)、聚苯乙烯(PS)、聚砜(PSU)、聚氯乙烯(PVC)、斯培特兰(Spectralon)以及热塑性烯烃弹性体(TPO)。优选热塑性塑料的涂覆熔点温度应在最低100华氏度到最高500华氏度的范围内。可使用硅烷偶合剂Y-Si(OR)3以增加上文所列的热熔性热塑性塑料中任一种的粘合强度。硅烷偶合剂还提供多个有利结果，包括改良的耐久性、机械特性、电子特性，和粘合剂分散液29。
热塑性塑料涂料可以含有填充化合物，其预期用于可包括(但不限于)以下的用途：着色(不透明或半透明)、抗UV、增强增粘特性、隔热、导热、导电、不导电、防水、增强水汽穿透、抑制水汽穿透、吸收光、折射光、传播声音、抑制声音、增强弹性、增强刚度、抗冲击、抗穿刺、抗磨损、增加体积、致密、防火、声音混响，以及吸收气态、液态或气相有毒化合物。
随后结合硅烷3描述涂布站34的细节。所描述的特定涂布站34仅是可以如何涂布长丝26的一个实例并且其它涂布技术在本发明的范畴内。站34包括涂覆辊36。涂覆辊36在其外表面内形成一系列周向沟槽38。标定各沟槽38的尺寸以接收单根长丝段26。在优选实施例中，长丝喂纱器的总数对应于涂覆辊36内的沟槽38的总数。
站34进一步包括供应辊42。供应辊在所属领域中是众所周知的。供应辊42的一个部分与一定体积的液化热塑性塑料44接触，并且供应辊42的另一部分接触涂覆辊36。以这种方式，供应辊42将选定体积的液化热塑性塑料44从供应辊42转移到涂覆辊36的表面。因此，用通过供应辊42转移的液化热塑性塑料44涂布放置在沟槽38内的单根长丝链26。
涂布站34进一步包括夹紧辊46，其以操作方式安置在涂覆辊36的顶部上。这个夹紧辊46与涂覆辊36的外周表面保持正面接触。夹紧辊46起在涂覆辊36旋转时将单根长丝段26保持在涂覆辊36上的相应沟槽38中的作用。
在涂布站34的末端任选地包括计量块48。优选的计量块48被设计用来从长丝26移除多余热塑性塑料。计量块48包括多个被设定尺寸以接收单根长丝段26的独立孔52。阀组48的出口包括使通过孔52移除的多余塑料流出的下部唇口54。可收集并且再使用流出的热塑性塑料或可将其丢弃。借此，计量块48控制对连续纤维段26的特定涂覆率和覆盖率以提供所要的粘合效果。上述热熔性热塑性塑料涂料/粘合剂所涂覆的膜厚度可以在最低.01密耳到50密耳并且最高50密耳的厚度范围内。可以相等或不等量涂覆涂料。
按以下操作涂布站34。从长丝喂纱器分配一系列未涂布的长丝26。随后，采用导辊将长丝导引到涂布站34的起点。随后，将长丝26导入涂覆辊36内的沟槽38中。当涂覆辊36旋转时，借助供应辊42持续向其供应液化的热塑性塑料44。涂覆辊36的持续旋转确保各长丝段26的整个外圆周面积完全被热塑性塑料浸没。随后，通过计量块48移除多余的热塑性塑料。所采用的特定计量块应取决于纤维垫的预期应用。涂布应维持完全的外圆周覆盖以便提供更大的接触面积，用于多向粘着所有周围的以及共同并入的纤维。覆盖率可在.1％长丝与100％长丝之间延伸。
最后，经涂布的长丝26借助导辊56导引离开涂布站。当长丝被导引离开时，准许热塑性塑料涂料44冷却并且固化。或者，可借助直接或间接冷却机制实施冷却步骤。最后，在线轴58上卷绕各经涂布的长丝段26。经涂布的长丝26可以另外通过缠绕、宽松/降落积累来积累或可以持续地供应到生产线。在所描述的实施例中，将经涂布的长丝26储存到线轴58上直至需要时。如下文更全面地描述，其后在构建纤维粘合垫28期间自线轴58分配经涂布的长丝26。
连续长丝纤维垫
当以上文所描述的方式涂布长丝26时，其便准备好形成纤维垫28。如图1中所指出，将预涂布的长丝26的线轴58放置在生产线20的起点。线轴58可呈长丝喂纱器形式。首先解开线轴58从而在成形台62上铺设长丝段26。为了完成这个，可以来回或左右的方式移动线轴56，从而各长丝段26以随机化图案沉积到成形台22上。理想地，铺设纤维26以便存在按重量计的均等分布。由于随机化图案，个别长丝26将在多个长丝相交点26(a)彼此相交。长丝相交点26(a)的密度将取决于所沉积的个别长丝段26的数目。所采用的长丝26的数目又将取决于垫28的预期用途而由操作员选择。
铺设长丝26的成形带62理想地由固体、网状或链接结构形成。带62优选地还包括液体固持特性以便为热塑性塑料涂料提供不粘表面并且进一步促进纤维之间的交叉粘着。成形带62也可以由有机或无机材料或二者的掺合物形成。
随后在带上将随机化长丝图案传输到包括多个顶部加热元件66的加热站64。在优选实施例中，加热元件66将长丝图案加热到约100°F与1,000°F之间的温度。可以采用直接或间接加热(或其组合)。因此，加热站64将长丝26加热到足以使热塑性塑料预涂料再液化或塑化的程度。再液化之后，相邻长丝上的涂料44彼此混合。当将长丝图案向下传输到带时，其冷却并且固化。可借助存在于加热站之后的环境温度实现冷却。通常，冷却几乎在加热站之后立即发生。采用热熔性热塑性塑料的优势是不需要二次冷却步骤来使塑料再固化。然而，如果需要，可以在加热站64下游采用冷却的成形线68。可间歇或连续地或以提高或降低温度的步骤提供加热和冷却步骤。长丝的加热和后续冷却使得长丝相交点粘合并且产生完全整合的粘合纤维垫。
通过热塑性塑料涂料获得的优选表面硬度可产生相当于在洛氏R硬度量表(Rockwell R Hardness scale)上最低约15到最高约150，或在肖氏A与D硬度量表(ShoreA and D Hardness scale)上最低约10到最高约70的硬度范围。所涂覆的热塑性塑料涂料/粘合剂的优选空气渗透率可在最低.01CFM/ft2/sec到最高1500CFM/ft2/sec的范围内(弗雷泽渗透率测试(Frazier Permeability Test)，其使用最大8mm到最小2mm喷嘴范围内的喷嘴)，因此涂料可能对于水汽运动的渗透几乎不可渗透或对水汽运动的渗透完全开放。
形成粘合纤维垫之后，可将其并入到复合建筑板中。这些建筑板生产步骤中的一些概述于与豪伯共同拥有的名称为“经玻璃强化的石膏板”的美国专利第6,524,679号中。出于所有目的，将'679专利的内容全部并入本文中。步骤大体上包括从纤维垫28顶上的承板72沉积石膏浆料。从浆料混合器74供应浆料。这个石膏浆料随后将形成建筑板的核心。其后，在石膏核心顶上铺设第二纤维垫76以形成复合板78。这个第二纤维垫76可以上文所描述的方式形成。或者，纤维垫28可由各种其它生产技术形成。最后，将复合板78传送到成形站80，在成形站80中将复合板78按压成均匀厚度。如所属领域中已知，取决于板的预期应用，随后可根据需要将所形成的板78切成段。
不连续长丝纤维垫
图2中展示一个替代性生产工艺。这个工艺在所有方面与结合图1概述的工艺相同。然而，图2的工艺在纤维垫构建中利用不连续长丝段。为了完成这个，如上所述从线轴58分配连续、未涂布的长丝段，但随后将其传送到长丝切断器82中。长丝切断器82用于剪切连续长丝段。可提供单个切断器82或可使用一组平行切断器。切断器82产生多个随机长度的更短纤维。切断的长丝的单根纤维长度应在.1厘米到45,720厘米范围内。这些短纤维随后聚集到累加器84和振荡器86中。振荡器86确保以随机化图案将单根切断纤维26传送到成形带62。理想地，铺设纤维26以便存在穿过成形带62的按重量计的均等分布。可采用称重带以检验所沉积纤维的密度。随机化纤维图案将包括多个长丝相交点。
纤维垫构建中所利用的长丝可以由有机纤维、无机纤维或有机与无机纤维的掺合物构成。纤维可以编织或非编织布置或其组合铺设。当通过热塑性塑料粘合时，所得垫将展现+X、-X、+Y、-Y、+Z以及-Z定向中的抗拉伸性。垫还将能够为任何方向中的拉力提供阻抗。另外，垫将具有提高的柔韧性、抗破裂与断裂性、复合物同化性以及耐热性。在多个不同应用中垫将具有生产阀门，所述应用包括垫、薄纱、织物或纱布。
垫特定应用于用作经玻璃强化的石膏板的复合建筑板中。然而，纤维垫亦可用作复合石膏建筑板，石膏纤维建筑板，水泥板，纤维水泥板，石膏纤维板壁，纤维水泥板壁，水泥板壁，石膏拱或檐，纤维石膏拱和檐，水泥拱和檐，纤维拱和檐，氧化镁建筑板，氧化镁拱和檐，氧化镁板壁，氧化镁屋顶板，经沥青浸渍的屋顶板，经沥青涂布的屋顶板，经沥青浸渍的建筑绝缘材料，经有机聚合物涂布、经无机物涂布的建筑绝缘材料，经有机物/无机物掺和涂布的建筑绝缘材料，并有连续或不连续或掺合连续与不连续(垫、纱布、薄纱、织物)材料的胶带，边角护条，地毯，强化胶合板，强化分层聚合复合物，以及强化模制或挤制的有机材料或无机材料或掺合有机物与无机物的材料(包括强化几何基材、强化刚性或柔韧性塑料管和强化圆柱体)。
在所有情形中，本发明的纤维垫不需要其它纸质表面薄片或背衬薄片。与常规垫构建相比，根据本发明构建的垫具有降低成本的益处。生产成本可降低多达30％到50％。
图5到6展示热塑性塑料涂料以不同密度程度在单根长丝上的涂覆。图5展示涂覆热塑性塑料之后的交叉纤维粘合。图6显示以更大密度涂覆以有效降低或封闭所得垫的渗透率的热塑性塑料。孔隙度可以从0％到95％变化。图7展示通过热塑性塑料完全涂布的单根纤维。取决于所要结果，即是否想要具有纤维/长丝抗剪切性的改良纤维/长丝，或是否想要垫的经改良的小半径柔韧性，或是否想要降低的空气或液体渗透率，可以调配热熔性热塑性塑料粘合剂以提供局部或全部的纤维/长丝覆盖或可以使其在纤维/长丝相交点/交叉点形成更多网状结构。在成形带上形成垫时，例如这一点的特性可以通过化学调配的变化或仅通过调节稠合温度实现。本发明的一个巨大优势是，单独的温度变化(而非需要传统热固化粘合剂技术的持久性再形成的改变)可以产生显著的产物变化/机能而不增加用于再调配粘合剂的成本。这个优势通过在形成垫、薄纱、织物或材料之前用热熔性热塑性塑料预涂布各纤维/长丝实现。
尽管已经依据某些实施例和大体相关的方法描述本发明，但对于所属领域的技术人员这些实施例和方法的更改和置换应为显而易知的。因此，实例实施例的以上描述并不限定或约束本发明。在不脱离本发明的精神和范畴的情况下，其它改变、替代和更改也是可能的。

Claims (7)

1.一种生产包括一或多个纤维垫的复合建筑板的方法，所述方法包含：
提供多个长丝喂纱器，所述多个长丝喂纱器中的每一个包括用热熔性热塑性塑料预涂布的连续长丝段；
以随机化图案在成形台上铺设各长丝段，所述随机化图案包括多个长丝相交点；
在所述成形台上将长丝的所述随机化图案加热到约100°F到1000°F之间的温度，热熔化各长丝段上的所述热熔性热塑性塑料预涂料；
将长丝的所述随机化图案冷却到环境温度，所述加热和冷却导致所述长丝相交点粘合，并产生第一纤维垫；
在所述纤维垫上沉积石膏浆料，所述沉积的石膏浆料形成所述复合建筑板的核心；
在所述石膏核心上方铺设第二纤维垫，以形成复合板；
将所述复合板传送到成形台，借以将所述复合板按压成均匀厚度。
2.一种生产包括一或多个纤维垫的复合建筑板的方法，所述方法包含：
提供连续长丝段；
用热塑性塑料粘合剂涂布所述长丝；
在成形台上将随机化图案馈给所述经涂布的长丝，所述随机化图案包括多个长丝相交点；
在所述成形台上加热所述随机化图案以熔化所述热塑性塑料粘合剂；
将所述随机化图案冷却到环境温度，所述加热和冷却导致所述长丝相交点粘合，并产生第一纤维垫；
在所述纤维垫上沉积石膏浆料，所述沉积的石膏浆料形成所述复合建筑板的核心；
在所述石膏核心上方铺设第二纤维垫，以形成复合板。
3.根据权利要求2所述的方法，其包含在所述成形台上沉积之前将所述经涂布的长丝切短成不连续段的另一步骤。
4.根据权利要求2所述的方法，其包含在涂布所述长丝之前将硅烷偶合剂Y-Si(OR)3添加到所述热塑性塑料粘合剂的另一步骤。
5.根据权利要求2所述的方法，其中所述热塑性塑料粘合剂以在约.01密耳到约50密耳之间的厚度涂覆。
6.根据权利要求2所述的方法，其中所述热塑性塑料粘合剂的熔点范围为100°F与500°F之间。
7.一种用于涂布连续长丝段的系统，所述系统包含：
多个长丝喂纱器，所述长丝喂纱器中的每一个供应长丝段；
热熔性热塑性塑料的供应，所述热熔性热塑性塑料经加热和液化；
具有带沟槽的外周表面的涂覆辊，所述沟槽中的每一个适于从长丝喂纱器接收长丝段；
邻近所述涂覆辊放置的供应辊，所述供应辊将一定体积的所述液化热塑性塑料传送到所述涂覆辊的外周表面，借以用液化热塑性塑料涂布所述沟槽内的长丝；
与所述涂覆辊的所述外周表面接触的夹紧辊，其中在所述长丝经涂布时，所述夹紧辊使所述长丝段保持在所述涂覆辊的所述沟槽内；
计量块，所述计量块包括多个用于接收所述长丝段的孔，所述计量块进一步包括用于从所述长丝段排出多余体积的液化热塑性塑料的流出唇口。
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