CN105637133B - 提供载体材料的方法 - Google Patents

提供载体材料的方法 Download PDF

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CN105637133B
CN105637133B CN201480056832.3A CN201480056832A CN105637133B CN 105637133 B CN105637133 B CN 105637133B CN 201480056832 A CN201480056832 A CN 201480056832A CN 105637133 B CN105637133 B CN 105637133B
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modulus
yarn
nonwoven layer
fiber nonwoven
polymer
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CN105637133A (zh
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淄吉普 Y·范德
M·伯克霍夫
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Lobona Co Ltd
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Lobona Co Ltd
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    • 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
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    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
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    • 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
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    • E—FIXED CONSTRUCTIONS
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
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Abstract

本发明提供生产载体材料的方法，所述载体材料包含纤维非织造层和沿着载体材料的纵向延伸的线，此方法包括以下步骤：供应纤维非织造层，供应包含纬纱的平纹棉麻织物，所述纬纱含有其熔融温度等于或低于在纤维非织造层中所含热塑性纤维的最低熔融温度的聚合物；并且将平纹棉麻织物与纤维非织造层进行热粘合。

Description

提供载体材料的方法
技术领域
本发明涉及一种提供载体材料的方法，所述载体材料包含纤维非织造层和沿着载体材料的纵向延伸的线。
背景技术
包含纤维非织造层的载体材料用于许多应用中，例如沥青屋顶膜、屋顶垫层片材和(带衬垫的)乙烯基地板覆盖材料。
在生产工艺中遇到的高温和/或高张力可能需要沿着载体材料的纵向添加线，尤其是高模量线，例如玻璃纱，从而耐受在生产期间沿着加工方向的高张力，尤其在高温下。这些载体是公知的，例如参见EP1372951，并且通常通过将大量的单根线、优选按照有规律的间隔在空间上分开地引入纤维非织造层中制备，这是直接在纤维非织造层的形成期间或通过将各个线层压到预制的纤维非织造层上进行的。
EP0239207A2公开了一种使用低熔点平纹棉麻织物生产造纸用毡的方法，其中棉絮进行针织，然后进行热处理。
但是，引入大量的单独线是十分复杂的工艺，需要大型纱架以将各个线从线轴解缠。当各个线在形成纤维非织造层期间被直接引入纤维非织造层中时，生产效率受到在形成纤维非织造层期间和在引入单独线期间的干扰的不利影响。
另外，为了确保沿着纵向延伸的各个线保持按照有规律的距离在空间上分开，必须将在各个线上的张力控制到相同的水平，因此对在解缠各个线期间的工艺控制提出了高要求。
所以，仍然需要一种改进的提供载体材料的方法，所述载体材料包含纤维非织造层和沿着载体材料的纵向延伸的线。
发明内容
本发明的目的是提供一种改进的生产载体材料的方法，所述载体材料包含纤维非织造层和沿着载体材料的纵向延伸的线。
本发明目的是通过一种提供二维载体材料的方法实现的，所述载体材料包含纤维非织造层和沿着载体材料的纵向延伸的线，此方法包括以下步骤：供应纤维非织造层，供应与纤维非织造层相邻且处于共平面的包含经纱和纬纱的平纹棉麻织物，并且将平纹棉麻织物与纤维非织造层进行热粘合，此方法的特征在于平纹棉麻织物包含纬纱，所述纬纱含有这样的聚合物：此聚合物的熔融温度等于或低于在纤维非织造层中所含纤维的最低熔融温度，并且此聚合物的熔融温度低于在平纹棉麻织物中所含的至少一部分经纱的熔融温度。
具体实施方式
将平纹棉麻织物与纤维非织造层进行热粘合，其中平纹棉麻织物包含纬纱，所述纬纱包含其熔融温度等于或低于在纤维非织造层中所含纤维的最低熔融温度的聚合物，使得能按照有效的方式确保在沿着载体材料的纵向延伸的线之间的距离。
如本领域技术人员所公知，平纹棉麻织物是由至少两组平行纱线组成的开放点阵结构，其中第一组平行纱线是在与第二组平行纱线成一定角度上取向的，通常按照90度角。第一组平行纱线可以通过化学粘合与第二组平行纱线连接，和/或第一组平行纱线可以与第二组平行纱线交织以形成织造平纹棉麻织物。优选，在平纹棉麻织物中的开孔具有在载体材料平面中的至少一个尺寸是至少1mm，优选至少2mm，更优选至少5mm。更优选，在平纹棉麻织物中的开孔具有在载体材料平面中的两个尺寸是至少1mm，优选至少2mm，更优选至少5mm。
载体材料表示基本上二维的结构，载体材料的厚度比载体材料的宽度和长度都小至少一个数量级，优选小至少两个数量级，更优选小至少三个数量级。
认为虽然包含纤维非织造层和由同时作为经纱和纬纱的玻璃纱组成的平纹棉麻织物的载体材料可以解决在载体材料经受高张力和/或高温期间的一些问题，但是在平纹棉麻织物中存在的玻璃纱作为纬纱可能导致在最终产物例如(带衬垫的)乙烯基地板覆盖材料、屋顶垫层片材或沥青屋顶膜中的表面不平整。
当纤维非织造层在高温下沿着横向收缩或压缩时，尤其当暴露于沿着加工方向的高张力时，作为纬纱所含的玻璃纱可以弯曲，即在压缩应力的作用导致纬纱弯曲或扭结。
在一个实施方案中，将在平纹棉麻织物中的纬纱设计成使得在平纹棉麻织物与纤维非织造层热粘合之后，各个纬纱仍然作为连续相存在，但不会显示硬挺性，这种硬挺性可能在(带衬垫的)乙烯基地板覆盖材料的生产期间导致表面缺陷，表面缺陷例如是印刷错误和/或表面不平整，或可能在沥青膜或屋顶垫层片材的生产期间导致表面不平整。
在一个实施方案中，在平纹棉麻织物中的纬纱在平纹棉麻织物与纤维非织造层进行热粘合期间完全熔融，使得纬纱在热粘合之后不再作为连续相存在。因为在与纤维非织造层热粘合之后在平纹棉麻织物中不再存在纬纱，所以防止了在(带衬垫的)乙烯基地板覆盖材料的生产期间形成表面缺陷，例如印刷错误和/或表面不平整，或防止了在沥青膜或屋顶垫层片材的生产期间形成表面不平整。
在一个实施方案中，将平纹棉麻织物与预制的纤维非织造层进行热粘合，即通过任何合适的固结技术进行固结，例如通过在两个压延辊之间压延纤维网，通过机器针刺法，或通过水刺法，通过超声粘合，通过热粘合，或通过任何其组合方式。
在一个实施方案中，在形成未固结的纤维非织造层之后直接将平纹棉麻织物与纤维非织造层进行热粘合，从而同时实现纤维非织造层的固结以及平纹棉麻织物与纤维非织造层的热粘合。在此实施方案中，不需要进行纤维非织造层的单独固结步骤，因此实现了更有效的生产工艺。
纤维非织造层可以含有热塑性聚合物纤维，从而向载体材料提供充足的撕裂强度和/或断裂伸长率。
在一个实施方案中，平纹棉麻织物的纬纱是主要由这样的聚合物制成的：此聚合物的熔融温度等于或低于在纤维非织造层中所含纤维的最低熔融温度。优选，平纹棉麻织物的纬纱是由这样的聚合物制成的：此聚合物的熔融温度比在纤维非织造层中所含热塑性纤维中包含的聚合物的最低熔融温度低至少10℃，优选低至少20℃，更优选低至少50℃。术语“主要由...制成”表示基于纬纱总重量计的至少60重量％、优选至少75重量％、更优选至少90重量％、更优选至少95重量％、甚至更优选至少99重量％、最优选100重量％的纬纱是由其熔融温度等于或低于在纤维非织造层中所含纤维的最低熔融温度的聚合物制成。
热塑性聚合物的熔融温度是通过差示扫描量热法(DSC)作为在以20℃/分钟的速率加热聚合物时的吸热熔融峰的最大值测定的。
在一个实施方案中，沿着载体材料的纵向延伸的线包含高模量纱，例如聚酯纱，例如聚对苯二甲酸乙二醇酯(PET)纱，聚酰胺纱，例如聚酰胺-6(PA6)纱，玻璃纱，芳族聚酰胺纱或碳纱和/或其它高模量纱或其任何组合，它们能耐受在用于生产沥青屋顶膜、屋顶垫层片材和(带衬垫的)乙烯基地板覆盖材料的工艺中遇到的高温和/或高张力。高模量纱可以具有至少1GPa的模量，优选至少5GPa，优选至少10GPa，优选至少15GPa，优选至少20GPa，优选至少25GPa，优选至少40GPa，更优选至少50GPa，最优选至少75GPa。优选，沿着纵向延伸的高模量线包含玻璃纱。优选，在载体中所含的所有沿着纵向延伸的高模量线是高模量纱，更优选所有高模量线是玻璃纱。
选择作为沿着载体纵向延伸的高模量线所含的高模量纱的类型和含量，使得载体的模量是至少25N/5cm，这是按照EN29073-3(08-1992)作为在2％的规定伸长率(LASE2％)下的载荷检测的，其中夹持速度是200mm/分钟。优选，载体的模量是至少50N/5cm，更优选至少100N/5cm，甚至更优选至少200N/5cm，最优选至少250N/5cm。
在本发明中，术语“纤维”理解为表示常产纤维和长丝。常产纤维是具有在2-200mm范围内的较短规定长度的纤维。长丝是具有大于200mm长度的纤维，优选大于500mm，更优选大于1000mm。长丝可以甚至是实质上无限的，例如当通过连续挤出和经由在喷丝头中的喷丝孔纺织长丝时形成。
纤维可以具有任何横截面形状，包括圆形、三叶形、多叶形或长方形，长方形显示宽度和高度，其中宽度可以显著大于高度，从而在此实施方案中的纤维是带子。另外，所述纤维可以是单组分、双组分或甚至多组分的纤维。
在一个实施方案中，在纤维非织造层中的纤维具有1-25分特(dtex)的线性密度，优选2-20分特，更优选5-15分特，最优选5-10分特，从而向载体提供加工稳定性和质量规整性，且同时保持对于从载体浸渍高粘度材料例如沥青或PVC增塑溶胶所需的足够结构开放性。单位“分特”定义了纤维细度，即每10000米的重量克数。
在载体中所含的纤维非织造层可以是任何类型的非织造物，例如通过公知方法制备的常产纤维非织造物，例如梳理方法、湿法成网方法或气流成网方法或其任何组合。纤维的非织造层也可以是由长丝组成的非织造物，其通过公知的纺粘方法制备，其中将长丝从喷丝头挤出，然后作为长丝网铺到传送带上，然后将此网粘合以形成纤维的非织造层；或通过两步法制备，其中将长丝纺制并缠绕到绕线筒上，优选以复丝纱的形式，然后将复丝纱解缠，并将长丝作为长丝网铺到传送带上，然后将此网粘合以形成纤维的非织造层。
优选，在纤维非织造层中的纤维是长丝，从而向载体和/或最终浸渍产品例如沥青屋顶膜、屋顶垫层片材或乙烯基地板覆盖材料提供较高的拉伸强度和/或较高的撕裂强度。
纤维的非织造层可以由基于在纤维非织造层中的纤维总重量计的至少50重量％的热塑性纤维组成，优选至少75重量％，更优选至少90重量％，甚至优选至少95重量％。增加在纤维非织造层中的热塑性纤维的量能提高拉伸强度和/或抗撕裂性和提高最终浸渍产品的挠性。
在一个实施方案中，纤维非织造层是由基于纤维非织造层中的纤维总重量计的100重量％热塑性纤维组成的。
用于组成纤维非织造层中的热塑性纤维的热塑性聚合物可以是任何类型的热塑性聚合物，其能耐受在沥青屋顶膜、屋顶垫层片材和乙烯基地板覆盖材料生产工艺中遇到的高温。在纤维非织造层中的热塑性纤维可以包含聚酯，例如聚对苯二甲酸乙二醇酯(PET)(基于DMT或PTA)，聚对苯二甲酸丁二醇酯(PBT)，聚对苯二甲酸亚丙基酯(PTT)，聚萘二甲酸乙二醇酯(PEN)和/或聚乳酸(PLA)，聚酰胺，例如聚酰胺-6(PA6)、聚酰胺-6,6(PA6,6)和/或聚酰胺-6,10(PA6,10)，聚苯硫醚(PPS)，聚乙烯酰亚胺(PEI)和/或聚甲醛(POM)，和/或它们的任何共聚物或任何共混物。
热塑性纤维可以含有基于纤维总重量计的至多25重量％的添加剂，例如纺丝助剂，填料，阻燃材料，UV抑制剂，结晶延迟剂/促进剂，增塑剂，热稳定剂，抗微生物添加剂，着色剂例如炭黑，或它们的任何组合。
在载体中所含的纤维非织造层的重量可以在40-250g/m2的范围内，优选45-200g/m2，优选50-150g/m2，更优选50-120g/m2，最优选60-100g/m2，从而保持载体的结构开放足以用浸渍材料例如沥青或PVC增溶溶胶进行浸渍，并提供浸渍材料向载体材料的充足力学粘合。纤维非织造层的较低重量导致在浸渍材料例如沥青或PVC增塑溶胶的消耗较少，但是纤维非织造层的过低重量会导致在PVC被凝胶化成粘结PVC材料之前PVC增塑溶胶(或沥青)从载体掉落。
在一个实施方案中，纤维的非织造层，优选由长丝组成的纤维非织造层，可以由单种类型的单组分纤维组成，其通过任何合适的粘合技术粘合，例如通过在两个压延辊之间压延纤维网，通过机器针刺法，通过水刺法，通过超声波粘合，或通过它们的任何组合方式。
在另一个实施方案中，纤维的非织造层，优选由长丝组成的纤维非织造层，可以包含两种类型的单组分纤维，其中每种类型的单组分纤维是由具有不同化学结构和具有不同熔点的聚合物组成。优选的是，两种不同聚合物的熔点相差至少10℃，优选相差至少20℃。更优选这些熔点相差至少50℃。这种产品可以通过使得纤维网经受在具有较低熔点的聚合物的熔点范围内的温度进行热粘合。
在另一个实施方案中，纤维的非织造层，优选由长丝组成的纤维非织造层，可以包含双组分纤维。双组分纤维是由具有不同化学结构的两种聚合物组成的纤维。可以基本上分为三种类型的双组分纤维:并列型、核-壳型和海-岛型的双组分纤维。在一个实施方案中，构成双组分纤维的两种聚合物的熔点相差至少10℃，优选相差至少20℃。更优选这些熔点相差至少50℃。这种包含双组分纤维的非织造层，当由并列型和/或核-壳型的双组分纤维组成时，可以通过使纤维网经受在具有较低熔点的聚合物的熔点范围内的温度进行热粘合。在一个优选实施方案中，非织造载体主要由核-壳型双组分纤维制成，优选由长丝制成。“主要”理解为表示在纤维非织造层中所含的纤维的至少50％、优选至少75％、更优选至少90％、甚至更优选至少95％、最优选100％是核-壳型双组分纤维。
优选，在核/壳型双组分纤维中的核/壳比率是在95/5体积％和5/95体积％之间。更优选，核/壳比率是在50/50体积％和95/5体积％之间。
在一个优选实施方案中，核/壳型双组分纤维中的壳是主要由聚酰胺组成，优选聚酰胺-6(PA6)，并且核主要由聚酯组成，优选聚对苯二甲酸乙二醇酯(PET)。
载体材料可以含有一个或多个其它层，每个层选自纤维非织造层和/或平纹棉麻织物，例如用于改进载体的质量均匀性和/或进一步降低在载体中所含的纤维非织造层的横向上的收缩和/或压缩。

Claims (26)

1.一种提供用于乙烯基地板覆盖材料、屋顶垫层片材或沥青屋顶膜的二维载体材料的方法，所述载体材料包含纤维非织造层和沿着载体材料的纵向延伸的线，所述沿着载体材料的纵向延伸的线包含具有至少1GPa模量的高模量纱，此方法包括以下步骤：供应纤维非织造层，供应与纤维非织造层相邻且处于共平面的包含经纱和纬纱的平纹棉麻织物，并且将平纹棉麻织物与纤维非织造层进行热粘合，此方法的特征在于平纹棉麻织物包含纬纱，其中基于纬纱总重量计的至少60重量％的纬纱是由聚合物制成，此聚合物的熔融温度等于或低于在纤维非织造层中所含纤维的最低熔融温度，并且此聚合物的熔融温度低于在平纹棉麻织物中所含的至少一部分经纱的熔融温度，其中沿着载体材料的纵向延伸的线是经纱。
2.根据权利要求1的方法，其中在平纹棉麻织物中的纬纱在平纹棉麻织物与纤维非织造层进行热粘合期间完全熔融，使得纬纱在热粘合之后不再作为连续相存在。
3.根据权利要求1-2中任一项的方法，其中将平纹棉麻织物与预制的纤维非织造层进行热粘合。
4.根据权利要求1-2中任一项的方法，其中在形成未固结的纤维非织造层之后直接将平纹棉麻织物与纤维非织造层进行热粘合，从而同时实现纤维非织造层的固结以及平纹棉麻织物与纤维非织造层的热粘合。
5.根据权利要求1或2的方法，其中纤维非织造层含有热塑性聚合物纤维。
6.根据权利要求1或2的方法，其中纤维非织造层包含两种类型的单组分纤维，这两种类型的单组分纤维是由具有不同熔点和不同化学结构的聚合物组成。
7.根据权利要求6的方法，其中两种类型单组分纤维的聚合物的熔点相差至少10℃。
8.根据权利要求1或2的方法，其中纤维非织造层包含由具有不同熔点和不同化学结构的两种聚合物组成的双组分纤维。
9.根据权利要求8的方法，其中双组分纤维中的两种组分的聚合物的熔点相差至少10℃。
10.根据权利要求1或2的方法，其中高模量纱具有至少5GPa的模量。
11.根据权利要求10的方法，其中选择高模量纱的类型和含量，使得载体的模量是至少25N/5cm，这是按照EN29073-3(08-1992)作为在2％的规定伸长率(LASE2％)下的载荷检测的，其中夹持速度是200mm/分钟。
12.根据权利要求6的方法，其中两种类型单组分纤维的聚合物的熔点相差至少20℃。
13.根据权利要求6的方法，其中两种类型单组分纤维的聚合物的熔点相差至少50℃。
14.根据权利要求8的方法，其中双组分纤维中的两种组分的聚合物的熔点相差至少20℃。
15.根据权利要求8的方法，其中双组分纤维中的两种组分的聚合物的熔点相差至少50℃。
16.根据权利要求1或2的方法，其中高模量纱具有至少10GPa的模量。
17.根据权利要求1或2的方法，其中高模量纱具有至少15GPa的模量。
18.根据权利要求1或2的方法，其中高模量纱具有至少20GPa的模量。
19.根据权利要求1或2的方法，其中高模量纱具有至少25GPa的模量。
20.根据权利要求1或2的方法，其中高模量纱具有至少40GPa的模量。
21.根据权利要求1或2的方法，其中高模量纱具有至少50GPa的模量。
22.根据权利要求1或2的方法，其中高模量纱具有至少75GPa的模量。
23.根据权利要求10的方法，其中选择高模量纱的类型和含量，使得载体的模量是至少50N/5cm，这是按照EN29073-3(08-1992)作为在2％的规定伸长率(LASE2％)下的载荷检测的，其中夹持速度是200mm/分钟。
24.根据权利要求10的方法，其中选择高模量纱的类型和含量，使得载体的模量是至少100N/5cm，这是按照EN29073-3(08-1992)作为在2％的规定伸长率(LASE2％)下的载荷检测的，其中夹持速度是200mm/分钟。
25.根据权利要求10的方法，其中选择高模量纱的类型和含量，使得载体的模量是至少200N/5cm，这是按照EN29073-3(08-1992)作为在2％的规定伸长率(LASE2％)下的载荷检测的，其中夹持速度是200mm/分钟。
26.根据权利要求10的方法，其中选择高模量纱的类型和含量，使得载体的模量是至少250N/5cm，这是按照EN29073-3(08-1992)作为在2％的规定伸长率(LASE2％)下的载荷检测的，其中夹持速度是200mm/分钟。
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