CN105637142A - 乙烯基地板覆盖材料 - Google Patents

乙烯基地板覆盖材料 Download PDF

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CN105637142A
CN105637142A CN201480056617.3A CN201480056617A CN105637142A CN 105637142 A CN105637142 A CN 105637142A CN 201480056617 A CN201480056617 A CN 201480056617A CN 105637142 A CN105637142 A CN 105637142A
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vinyl floor
polymer
carrier
fiber nonwoven
nonwoven layer
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Y·范德淄吉普
M·伯克霍夫
L·斯迪格特
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Freudenberg Performance Materials BV
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Bonar BV
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    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/06Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/02Layered 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
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/02Layered 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
    • B32B5/028Net structure, e.g. spaced apart filaments bonded at the crossing points
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/002Inorganic yarns or filaments
    • D04H3/004Glass yarns or filaments
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02Non-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
    • D04H3/04Non-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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0011Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/006Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the textile substrate as base web
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0223Vinyl resin fibres
    • B32B2262/0238Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10Inorganic fibres
    • B32B2262/101Glass fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54Yield strength; Tensile strength
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00Buildings or parts thereof
    • B32B2419/04Tiles for floors or walls
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/02Synthetic macromolecular fibres
    • D06N2201/0218Vinyl resin fibres
    • D06N2201/0236Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/08Inorganic fibres
    • D06N2201/082Glass fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/10Conjugate fibres, e.g. core-sheath, side-by-side
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2209/00Properties of the materials
    • D06N2209/10Properties of the materials having mechanical properties
    • D06N2209/103Resistant to mechanical forces, e.g. shock, impact, puncture, flexion, shear, compression, tear
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N2211/00Specially adapted uses
    • D06N2211/06Building materials
    • D06N2211/066Floor coverings

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)
  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)

Abstract

本发明提供乙烯基地板覆盖材料,其中乙烯基地板覆盖材料包含载体,所述载体包含含有热塑性纤维的纤维非织造层和沿着乙烯基地板覆盖材料的纵向延伸的高模量线,用于消除在乙烯基地板覆盖材料中的褶皱并且用于防止在乙烯基地板覆盖材料中形成印刷错误和/或表面不平整。

Description

乙烯基地板覆盖材料
描述:
本发明涉及乙烯基地板覆盖材料。
乙烯基地板覆盖材料基本上可以通过两种不同的方法制备。第一种方法包括提供具有受控厚度的PVC压延粘结片材,然后将其层压到背衬材料上,例如参见US2008/0193697A1。因为PVC压延片材已经是粘结材料,所以背衬材料通常不进行高温处理,并且向背衬施加的张力通常较低。
第二种制备乙烯基地板覆盖材料的方法包括提供PVC增塑溶胶,并将PVC增塑溶胶浸渍到载体材料中。在浸渍载体材料之后,PVC增塑溶胶在高温下凝胶化,从而得到PVC粘结层。
例如,带衬垫的乙烯基地板覆盖材料可以通过将数层基于PVC的层涂覆到载体材料上制备,其中每个PVC层具有其自身的功能。
载体被PVC增塑溶胶层浸渍,其在高温、通常在140-170℃下进行凝胶化,同时经浸渍的载体与热(金属)辊的表面接触。然后,将含有发泡剂的PVC增塑溶胶的发泡层涂覆到已凝胶化的浸渍层上,其然后也在高温下凝胶化。
使用印刷装置将所需的油墨图案施涂到凝胶化的发泡层上。在此印刷层的顶部上施涂清澈透明的PVC增塑溶胶层作为耐磨层,耐磨层再次在高温下凝胶化。在底部侧,可以施涂含有较大量发泡剂的可发泡性PVC增塑溶胶的背衬层。在发泡层和背衬层的PVC增塑溶胶中的发泡剂是在固化步骤中在比凝胶化温度更高的温度、通常在170-230℃下进行活化,从而发泡并且固化在发泡层和背衬层中的PVC以获得带衬垫的乙烯基地板覆盖材料。
含有由热塑性纤维组成的非织造载体的带衬垫的乙烯基地板覆盖材料是公知的,例如参见FR2013722A1和WO2005/118947A1。与基于非热塑性纤维的载体相比,这些由热塑性纤维组成的非织造载体向带衬垫的乙烯基地板覆盖材料提供了更好的抗撕裂性和挠性。
FR2013722A1公开了由具有氯乙烯涂层的尼龙(聚酰胺)长丝制备的非织造垫,其可以用作地板覆盖材料。非织造垫是通过在长丝交叉点处的氢键粘合的。
WO2005/118947A1公开了非织造载体,其中非织造物由不同的聚合物制备,并且非织造载体是通过来自在非织造载体中所含长丝的聚合物进行热粘合的。
WO2008/039262A1公开了湿法成网常产纤维非织造物作为载体用于具有改进的挺度的带衬垫乙烯基地板覆盖材料。
但是,观察到含有由热塑性纤维组成的非织造载体的乙烯基地板覆盖材料会在乙烯基地板覆盖材料生产工艺的加工过程中出现褶皱,这些褶皱基本上沿着乙烯基地板覆盖材料的加工方向延伸,这导致低品质的乙烯基地板覆盖材料或者甚至不能接受的产品、即废品,这取决于褶皱的量和幅度。
虽然用于乙烯基地板覆盖材料且包含含有热塑性纤维的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(scrim)的载体可以减少在乙烯基地板覆盖材料中沿着加工方向延伸的褶皱的形成,但是具有玻璃纱作为纬纱的平纹棉麻织物可能根据在乙烯基地板覆盖材料的生产工艺中遇到的实际张力和/或温度而引起在最终乙烯基地板覆盖材料中的表面不平整,和/或可能引起在施涂到凝胶化发泡层上的所需油墨团案中的印刷错误。
本发明的目的是提供一种乙烯基地板覆盖材料,其包含载体材料,所述载体材料包含含有热塑性纤维的非织造层,所述材料在乙烯基地板覆盖材料的加工方向上不显示褶皱或显示至少较少和/或较小的褶皱,且不会显示表面不平整或印刷错误。
本发明目的是通过权利要求1的乙烯基地板覆盖材料实现的。
沿着乙烯基地板覆盖材料的纵向、即加工方向延伸的高模量线的存在能防止或至少减少在乙烯基地板覆盖材料中形成沿着纵向延伸的褶皱。认为沿着纵向延伸的高模量线的存在降低了在载体中的含热塑性纤维的纤维非织造层中沿着加工方向的应变,所述应变是来自在乙烯基地板覆盖材料生产工艺中遇到的高张力。因为沿着纵向延伸的高模量线降低了加工方向上的应变,所以纤维的非织造层将显示在横向上较少的压缩和/或收缩。认为在纤维非织造层中的褶皱是由于在纤维非织造层的质量规整性方面的不均匀处的应力-应变行为发生局部变化引起的。
在一个实施方案中,乙烯基地板覆盖材料是带衬垫的乙烯基地板覆盖材料。
在本发明范围内,术语“载体”或“载体材料”理解为表示适合用PVC增塑溶胶浸渍的材料。
术语“背衬”或“背衬材料”理解为表示适合用PVC的压延粘结片材进行层压的材料。背衬粘附到PVC片材上。
对于用于(带衬垫的)乙烯基地板覆盖材料的载体而言的一般要求是为了在载体全部宽度上规整地施涂浸渍层所必需的充分表面平整性,即在载体表面上的充分均匀厚度。另外,对于PVC增塑溶胶均匀地穿透载体而言需要充分的结构开放性,从而在顶层和发泡的背衬层之间具有充足的脱层强度。另一方面,载体材料的结构应当不过于开放,从而在PVC被凝胶化成粘结的PVC材料之前防止PVC增塑溶胶从载体掉落。
在乙烯基地板覆盖材料的一个实施方案中,纤维的非织造层和沿着纵向延伸的高模量线可以在乙烯基地板覆盖材料生产工艺中单独地提供,只要在乙烯基地板覆盖材料生产工艺中的张力被施加到载体的全部组分上即可,包括纤维的非织造层和沿着纵向延伸的高模量线。
载体可以包含一个或多个其它层,每个层选自纤维非织造层、平纹棉麻织物和/或沿着加工方向延伸的高模量线,例如用于改进载体的质量均匀性和/或进而降低在载体中所含的纤维非织造层沿着横向的收缩和/或压缩。
优选,纤维非织造层和沿着纵向延伸的高模量线以及任选的其它层是作为单个的整合载体提供的,其中沿着纵向延伸的高模量线和纤维非织造层(以及任选的其它层)彼此连接形成整合的载体。沿着纵向延伸的高模量线和纤维非织造层彼此之间的连接可以通过任何公知的合适方法进行,例如通过使用粘合剂例如胶水和/或热熔体进行,或者通过热粘合进行,例如使用热空气粘合或压延,和/或通过机械粘合方法进行,例如缝合、机械针织和/或流体交缠,例如水刺法。术语“与…连接”理解为也包括这样的情况:其中沿着纵向延伸的高模量线位于两个纤维非织造层之间(即,包埋的),其中纤维非织造层是通过任何合适的方法在高模量线之间彼此粘合的,从而通过用彼此粘合的两个纤维非织造层中的纤维进行包封而将沿着纵向延伸的高模量线整合到载体中。
优选,整合载体的纤维非织造层和沿着纵向延伸的高模量线是通过热粘合和/或通过机械粘合方法彼此连接的,使得不需要施涂额外的粘合剂,并且得到不含粘合剂的载体。施涂粘合剂的操作需要使用额外的设备和额外的原料。
更优选,纤维非织造层和沿着整合载体纵向延伸的高模量线是通过热粘合彼此连接的,使得不需要使用机械粘合方法。机械粘合方法本身存在损伤沿着纵向延伸的高模量线的风险。优选,纤维非织造层和沿着整合载体纵向延伸的高模量线仅仅通过热粘合彼此连接。
在一个实施方案中,在载体中所含的沿着纵向延伸的高模量线包含高模量纱,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,它们能耐受在乙烯基地板覆盖材料生产工艺中遇到的温度。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。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。
选择在载体中作为沿着纵向延伸的高模量线所包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PVC增塑溶胶均匀透过载体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/或抗撕裂性并提高乙烯基地板覆盖材料的挠性。
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,其能耐受在乙烯基地板覆盖材料生产工艺中遇到的温度。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透过PVC增塑溶胶的浸渍层和提供浸渍层向载体的足够力学粘合。纤维非织造层的较低重量导致在浸渍层中的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)。
在乙烯基地板覆盖材料的一个实施方案中,沿着乙烯基地板覆盖材料的纵向延伸的高模量线是包含在平纹棉麻织物中,其中平纹棉麻织物的纬纱主要由这样的聚合物制成:此聚合物的熔融温度等于或低于在纤维非织造层中所含热塑性纤维中包含的聚合物的最低熔融温度。优选,平纹棉麻织物的纬纱是由其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℃的聚合物制成。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热塑性纤维中包含的聚合物的最低熔融温度的聚合物组成。
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。
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。
在平纹棉麻织物中,主要由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中包含的聚合物的最低熔融温度的聚合物制成的纬纱的存在使得在平纹棉麻织物中的纬纱能与纤维非织造层进行热粘合,由此有效地将平纹棉麻织物与纤维非织造层进行热粘合。
在一个实施方案中,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,且不会在乙烯基地板覆盖材料的生产期间显示导致表面缺陷的硬挺性,表面缺陷例如是印刷错误和/或表面不平整。
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。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(连续的)纬纱,所以在乙烯基地板覆盖材料的生产期间不会出现表面缺陷,例如印刷错误和/或表面不平整。
在一个实施方案中,在平纹棉麻织物中不包含载体的沿着纵向延伸的高模量线。沿着纵向延伸的高模量线因此没有通过沿着横向、也称为纬向延伸的线彼此连接。
惊奇地发现,包含含热塑性纤维的纤维非织造层和沿着乙烯基地板覆盖材料的纵向延伸的高模量线的载体能够防止或至少减少沿着乙烯基地板覆盖材料的纵向延伸的褶皱的形成,并且防止或至少减少在发泡层和任选在背衬层中的PVC增塑溶胶进行发泡和固化之后在(带衬垫的)乙烯基地板覆盖材料中形成表面不平整。
虽然观察到包含玻璃纱同时作为经纱和纬纱的平纹棉麻织物能完全消除在乙烯基地板覆盖材料中沿着加工方向形成褶皱,但是根据在乙烯基地板覆盖材料生产工艺中遇到的实际张力和/或温度,具有玻璃纱作为纬纱的平纹棉麻织物引起在最终乙烯基地板覆盖材料中的表面不平整性,和/或可以引起在施涂到凝胶化和任选发泡的层上的所需油墨图案中的印刷错误。
乙烯基地板覆盖材料包含载体,所述载体包含含有热塑性纤维的纤维非织造层以及沿着乙烯基地板覆盖材料的纵向延伸的高模量线,认为这种载体能防止纬纱的弯曲,即当纤维非织造层沿着横向收缩或压缩时,纬纱在压缩应力作用下的弯曲或扭结。不限于任何理论,认为在浸渍层中的PVC增塑溶胶进行凝胶化期间,平纹棉麻织物的纬纱的弯曲会导致凝胶化浸渍层的不平整表面,尤其当纬纱的弯曲是从形成载体表面的平面出现时,这种情况如图1所示。平纹棉麻织物包含经纱(2)和纬纱(1)。纬纱(1)已经在PVC增塑溶胶的浸渍层的凝胶化期间弯曲。由于纬纱(1)的弯曲,浸渍层具有不平整的上表面(3)和不平整的下表面(4)。由于凝胶化浸渍层的不平整上表面(3),局部变化量、即不同层厚度(D1,D2)的含发泡剂的PVC增塑溶胶将作为(发泡)层被涂覆到凝胶化浸渍层的不平整表面(3)上。涂层可以直接在涂覆之后和在PVC增塑溶胶进行凝胶化之后仍然具有平滑的上表面(5)。可以将所需的油墨图案和耐磨层(6)施涂到涂层的表面(5)上。在发泡层固化(发泡)之后,含有发泡剂的PVC增塑溶胶的局部变化量(D1,D2)将导致在最终带衬垫乙烯基地板覆盖材料的表面(8)中的表面不平整性。在施涂较大量(D1)的含发泡剂的PVC增塑溶胶的位置,在发泡层发泡之后,带衬垫的乙烯基地板覆盖材料的最终厚度将大于在施涂较小量(D2)的含发泡剂的PVC增塑溶胶的位置处的最终厚度,这导致在最终带衬垫乙烯基地板覆盖材料的表面(8)中的表面不平整性。
另外,认为由于平纹棉麻织物的纬纱(1)在沿着纤维非织造层横向收缩或压缩时发生弯曲,凝胶化浸渍层的不平整表面(3,4)使得在凝胶化的发泡层(5)上局部施涂所需油墨图案的操作变得复杂。虽然发泡层的涂覆和随后凝胶化可以形成用于油墨的平整表面(5),但是将难以确保在印刷装置和在待印刷表面上的凝胶化发泡层的表面(5)之间施加均匀的压力,尤其当实际压力是通过与不平整的凝胶化浸渍层的相反表面(4)直接接触的支撑辊提供的支撑来确定时。最后,可以将可发泡性PVC增塑溶胶的背衬层(7)涂覆到不平整的凝胶化浸渍层的相反表面(4)上。由于凝胶化浸渍层的不平整的下表面(4),局部变化量、即具有不同层厚度的含发泡剂的PVC增塑溶胶也将作为背衬层施涂到凝胶化浸渍层的不平整表面(4)上。因为背衬层可以进行压花步骤,并且当将带衬垫的乙烯基地板覆盖材料安装在地板上时看不到其背面,所以此效果是不太重要的。
在平纹棉麻织物中的由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中包含的聚合物的最低熔融温度的聚合物制成的纬纱可以包含适合于在用于形成带衬垫乙烯基地板覆盖材料用的整合载体的热粘合工艺中遇到的温度下熔融或至少软化的任何聚合物,从而使得纬纱失去它们的结构形状。纬纱的聚合物可以优选选自聚酯,优选共聚酯,聚酰胺,优选共聚酰胺,聚烯烃例如聚丙烯或聚乙烯,和/或它们的任何共聚物或任何共混物。

Claims (11)

1.一种乙烯基地板覆盖材料,其包含载体,其中载体包含含有热塑性纤维的纤维非织造层和沿着乙烯基地板覆盖材料的纵向延伸的高模量线,其中高模量线是彼此分开的,优选按照有规律的距离分开,并且其中热塑性纤维是热塑性长丝。
2.根据权利要求1的乙烯基地板覆盖材料,其中高模量线和含有热塑性纤维的纤维非织造层彼此连接以形成整合的载体。
3.根据前述权利要求中任一项的乙烯基地板覆盖材料,其中沿着乙烯基地板覆盖材料的纵向延伸的高模量线具有至少1GPa的模量,优选至少5GPa,优选至少10GPa,优选至少15GPa,优选至少20GPa,更优选至少25GPa。
4.根据前述权利要求中任一项的乙烯基地板覆盖材料,其中选择沿着乙烯基地板覆盖材料的纵向延伸的高模量线的类型和含量,使得载体的模量是至少25N/5cm,优选至少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,这是按照EN29073-3(08-1992)作为在2%规定伸长率下的载荷检测的。
5.根据权利要求1-4中任一项的乙烯基地板覆盖材料,其中沿着纵向延伸的高模量线不包含在平纹棉麻织物中。
6.根据权利要求1-4中任一项的乙烯基地板覆盖材料,其中沿着乙烯基地板覆盖材料的纵向延伸的高模量线包含在平纹棉麻织物中,其中平纹棉麻织物的纬纱是由这样的聚合物制成:此聚合物的熔融温度等于或低于在纤维非织造层中所含热塑性纤维中包含的聚合物的最低熔融温度。
7.根据权利要求6的乙烯基地板覆盖材料,其中平纹棉麻织物的纬纱是由这样的聚合物制成: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℃。
8.根据权利要求1-7中任一项的乙烯基地板覆盖材料,其中纤维非织造层包含两种类型的单组分长丝,每种类型的单组分长丝是由具有不用熔点和不同化学结构的聚合物组成。
9.根据权利要求8的乙烯基地板覆盖材料,其中两种类型单组分长丝的聚合物的熔点相差至少10℃,优选相差至少20℃,更优选相差至少50℃。
10.根据权利要求1-7中任一项的乙烯基地板覆盖材料,其中纤维非织造层包含由具有不用熔点和不同化学结构的两种聚合物组成的双组分长丝。
11.根据权利要求10的乙烯基地板覆盖材料,其中双组分长丝的两种组分的聚合物的熔点相差至少10℃,优选相差至少20℃,更优选相差至少50℃。
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