CN105723023A - 弹性无纺垫 - Google Patents

弹性无纺垫 Download PDF

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Publication number
CN105723023A
CN105723023A CN201480057252.6A CN201480057252A CN105723023A CN 105723023 A CN105723023 A CN 105723023A CN 201480057252 A CN201480057252 A CN 201480057252A CN 105723023 A CN105723023 A CN 105723023A
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CN
China
Prior art keywords
woven pad
weight
pad
woven
synthetic fibers
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Granted
Application number
CN201480057252.6A
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CN105723023B (zh
Inventor
J·吴
P·A·克勒特
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Owens Corning Intellectual Capital LLC
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OCV Intellectual Capital LLC
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING 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
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
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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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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
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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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    • 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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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

本发明提供了一种无纺短切纤维垫，该无纺垫含有约10?约100重量％的玻璃纤维和约5?约50重量％的合成纤维的混合物。所述无纺垫含有含粘结剂树脂和硅烷偶联剂的粘结剂组合物。还发现通过配制软的但强的粘结剂组合物并将之用于形成垫子，该无纺垫的物理性能(例如弹性、抗张强度)可以得到改善。

Description

弹性无纺垫
相关申请
本申请要求在2013年10月16日提交的、名称为“Flexible Non-WovenMat”的临时申请号61/891,564的优先权，并通过引用将其并入本文中。
技术领域
本发明涉及一种具有改善的弹性的无纺纤维垫(non-woven fiber mats)，以及制备该改善的弹性的无纺纤维垫的方法，以用于强化物体的制备。
背景技术
传统的无纺垫包括通过合适的树脂粘结剂结合在一起的纤维网。增强纤维(Reinforcement fibers)例如玻璃纤维常用于各种各样的技术中，并且可以用于形成连续或短切丝(filaments)、原丝(strands)、粗纱(rovings)、织物(woven fabric)、无纺织物(nonwoven fabrics)、网(meshes)和基布(scrims)，例如以加强聚合物。增强的聚合物复合材料能够通过多种方式由聚合物基质材料、加强材料和其他成分制得。这样的复合材料是采用增强纤维(其为所得的复合材料提供了尺寸稳定性(dimensional stability)和良好的机械性能)形成。
例如，玻璃纤维能提供尺寸稳定性是因为它们不会随着环境条件变化而收缩或伸长。并且，玻璃纤维具有高的抗张强度(tensile strength)、耐热性、抗湿性和高的导热性。
无纺纤维垫通常用于拉挤成型工艺(pultrusion processes)以形成拉挤成型部件(pultruded parts)。一般地，拉挤成型包括将纤维垫浸渍有合适的树脂材料，并将浸渍后的垫子通过热模(heated die)。通过将浸渍的且加固的垫子通过所述热模，可以使得该垫子形成所需的形状且使得树脂固化以将该垫子结合在一起。从所述热模中出来的复合材料部件随后则被切为所需长度。
所述拉挤成型工艺的连续性将有利于生产具有任何所需长度的复合材料。然而，拉挤成型工艺也具有许多的问题。其中一个问题在于树脂浴(resinbath)。通常采用的是热固性树脂，该树脂一般需要采用挥发性的不饱和单体例如苯乙烯和/或甲基丙烯酸甲酯进行制备。苯乙烯是一种强溶剂，其可以轻易地溶胀(swell)并降解应用于加强垫中的粘结剂。这样的粘结剂降解能导致纤维垫被弱化从而不能承受拉挤成型工艺中施加的强拉力。
连续丝垫(continuous filament mats)和涂布有粘结剂的短切原丝垫(chopped strand mats)都可以用于拉挤成型工艺。尽管连续丝垫为弹性的、整合的且对苯乙烯具有优良的耐受性，但是它们仍具有多种缺点。比如，连续丝垫制备成本高，因为连续丝垫的制造需要在低速下进行，例如50-75英尺每分钟(fpm)。此外，由于采用了玻璃长丝来形成垫子，使得连续丝垫将产生具有差的表面抛光的叠层。此外，连续丝垫较密实，从而会增加最终部件的重量，这可能并不是所希望的特点。
相反地，短切原丝垫比连续丝垫的制备成本低，这是由于其制备可以在更快的速度下进行(即500-1500fpm)。此外，短切原丝垫本质上为充分分散的纤维，其为拉挤成型部件提供了比连续丝垫更平滑的外观。此外，短切原丝垫由于未向叠层增加过多的重量从而有利于“空间填充(space filling)”。尽管短切原丝垫具有这些正面的性质，但是采用热固性粘结剂的它非常的硬，因此难以形成复杂的形状。此外，短切原丝垫的刚性会导致消费者产生不舒服的感受。
因此，仍存在对具有足以形成复杂形状的弹性的、能与树脂基质相容的、重量轻但具有足够的强度的无纺垫的需求，从而满足于下游工艺的应用(例如拉挤成型和石膏墙板的形成)。
发明内容
在本发明的一些具体实施方式中，无纺短切原丝垫(non-woven choppedstrand mat)的物理性质能够通过配制粘结剂组合物而得到改善，从而在使用时具有优良的抗张强度和良好的弹性并结合有合适的纤维设计。
在本发明的一些具体实施方式中，提供了弹性的无纺短切原丝垫，其含有约10-约100重量％的玻璃纤维和约0-约90重量％的合成纤维的混合物。该无纺短切原丝垫还含有含粘结剂树脂和硅烷偶联剂的粘结剂组合物。
根据本发明的进一步的具体实施方式，还发现了所述合成纤维包括聚丙烯、聚酯及其组合中的至少一种。
根据本发明的一些具体实施方式，所述粘结剂树脂包括热固性材料、热塑性材料中的至少一种或它们的组合。一些具体实施方式包括热固性材料和热塑性材料的混合物，例如，丙烯酸材料(acrylic material)、脲醛材料(ureaformaldehyde material)中的一种或多种或其组合与乙烯醋酸乙烯酯(ethylenevinyl acetate)的混合物。本发明的一些具体实施方式包括含有约50-100重量％的热塑性材料和0-约50重量％的热固性材料的粘结剂树脂。
根据本发明的一些具体实施方式，用于弹性无纺垫中的粘结剂组合物耐受苯乙烯单体。
根据一些具体实施方式，所述弹性的无纺短切原丝垫在轴向(machinedirection)上具有至少30lb的轴向平均抗张强度(tensile strength)，且在横向上具有至少20lb的平均抗张强度。“轴向”是指与垫子在制造过程中移动方向一致的方向。垫子还可以具有约2000-约7000毫克力(mgf)的MD(轴向)格利刚度(Gurley stiffness)，这是由格利刚度测试机测得的。
在本发明的多种具体实施方式中，提供了一种拉挤成型复合材料产品。该拉挤成型复合材料产品包括多种浸渍有热固性树脂的粗纱和弹性的无纺短切原丝垫。多种具体实施方式中的所述弹性无纺垫含有约10-约95重量％的玻璃纤维和约5-约90重量％的合成纤维的混合物。该无纺短切原丝垫还含有含粘结剂树脂和硅烷偶联剂的粘结剂组合物。
此外，根据本发明的另一种具体实施方式，所述粘结剂树脂可以包括热固性材料、热塑性材料中的至少一种或它们的组合。一些具体实施方式的粘结剂树脂包括热固性材料和热塑性材料的混合物，例如，丙烯酸材料、脲醛材料中的一种或多种或其组合与乙烯醋酸乙烯酯的混合物。本发明的一些具体实施方式的粘结剂树脂含有约50-100重量％的热塑性材料和0-约50重量％的热固性材料。
而在本发明的其他具体实施方式中，提供了一种石膏墙板(gypsum wallboard)。所述石膏墙板包括石膏芯(gypsum core)以及至少一种弹性无纺垫。在一些具体实施方式中，该弹性的无纺短切原丝垫含有约10-约95重量％的玻璃纤维和约5-约90重量％的合成纤维的混合物。所述无纺垫还含有含粘结剂树脂和硅烷偶联剂的粘结剂组合物。
具体实施方式
在本文中描述了或提出了多种实施方式，采用与这些描述或提出的相似或相当的方法和材料的其他实施方式也包括在本发明中。
除非额外定义，本文中使用的全部技术术语和科学术语都具有本发明所属领域中的技术人员通常理解的含义。此外，除非额外的指出，本文中的成分浓度指的是这些成分在母料或浓缩物中的浓度，这是约定俗成的。
本发明涉及一种具有改善性能的弹性的无纺短切原丝垫(通常也指作无纺垫)。在一些具体实施方式中，该弹性无纺垫展现出改善的机械强度，例如高轴向抗张强度和横向抗张强度，且同时表现出改善的弹性。本发明的无纺垫的柔软度和弹性将改善下游工艺，例如，具有复杂形状的拉挤成型产品的形成和/或石膏墙板的制备。此外，根据多种具体实施方式，本发明的弹性无纺垫能够耐受苯乙烯和聚酯(可能存在于拉挤成型工艺中采用的树脂配方中)。
本发明的一些具体实施方式涉及一种弹性无纺垫，其可以用于多种下游工艺中，例如用于拉挤成型工艺和石膏墙板的制备中。所述无纺垫具有很多优势，包括具有非常好的弹性。例如，在一些具体实施方式中，所述无纺垫展现了低于6000mgf的降低的刚度，或者低于5000mgf的降低的刚度。该刚度水平相对于具有7000mgf左右刚度的传统无纺垫来说降低了非常多。
本发明的所述弹性无纺垫可以含有多种纤维，包括玻璃纤维、合成纤维中的任意一种或它们的混合物。所述玻璃纤维可以通过任何一种类型的玻璃制得。玻璃纤维的实例包括A-型玻璃纤维、C-型玻璃纤维、E-型玻璃纤维、S-型玻璃纤维、ECR-型玻璃纤维(例如商业可得的购自Owens Corning的玻璃纤维)、Hiper-texTM、毛绒玻璃纤维(wool glass fibers)及其组合。所述无纺垫中可用的其他增强纤维例如矿物纤维(mineral fibers)、碳纤维、陶瓷纤维、天然纤维和/或合成纤维也可以认为是在本发明构思范围内。本发明中采用的术语“天然纤维”指的是从植物的任意部分提取得到的植物纤维，包括但不限于，茎、种子、叶、根或韧皮部。适用于作为增强纤维材料的天然纤维的实例包括玄武岩(basalt)、棉、黄麻(jute)、竹子、苎麻(ramie)、甘蔗渣(bagasse)、大麻(hemp)、椰子壳(coir)、亚麻、洋麻(kenaf)、剑麻(sisal)、亚麻花(flax)、赫纳昆(henequen)和它们的组合。本文中采用的术语“合成纤维”指的是具有合适的加强特性的任何人造纤维，例如聚酯、聚乙烯、聚对苯二甲酸乙二醇酯、聚丙烯、聚酰胺、芳纶(aramid)和聚芳族聚酰胺纤维(poly aramid fibers)，及它们的组合。
在一些具体实施方式中，用于形成根据本发明的无纺垫的纤维包括玻璃纤维和合成树脂纤维(例如聚合物纤维)的混合物。根据多种具体实施方式，所述聚合物纤维包括这些由聚丙烯、聚酯或它们的组合制得的纤维。在一些具体实施方式中，所述聚合物纤维由聚对苯二甲酸乙二醇酯(PET)制得。
在一些具体实施方式中，用于形成根据本发明的无纺垫的纤维含有约10-约100重量％的玻璃纤维和约0-约90重量％的聚合物纤维的混合物。在一些具体实施方式中，所述纤维含有约50-约90重量％的玻璃纤维和约10-约50重量％的聚合物纤维的混合物，或者含有约75-约90重量％的玻璃纤维和约10-约25重量％的聚合物纤维的混合物。
所述玻璃纤维可以通过本领域技术人员所公知的常规的方法制得。例如，所述玻璃纤维可以通过连续化生产工艺制得，其中熔融玻璃通过“套管(bushing)”的孔，由此形成熔融玻璃的流体固化成丝，而后将该丝结合在一起形成纤维、“粗纱”、“原丝”或类似的。
在玻璃纤维从套管拉出后，任选采用含水定型组合物(sizingcomposition，也称作定型剂(size))涂布于该纤维上。对所述定型组合物并无限定，可以为本领域技术人员公知的任意定型剂。通常的定型组合物可以含有润滑剂以保护纤维免于磨损，含有成膜树脂以帮助纤维与形成复合材料(采用了该纤维)的基质或基体的聚合物结合，以及含有偶联剂以改善成膜树脂在玻璃纤维表面的粘附性。所述定型组合物可以采用常规的方式进行涂布，例如通过锟涂机(application roller)或者直接将定型剂喷涂于所述纤维上。定型剂可以在随后的处理中保护玻璃纤维免于破损，有助于阻止丝间磨损，确保了玻璃纤维原丝的完整性，促进了形成原丝的玻璃丝的相互连接等。
在用所述定型组合物处理玻璃纤维后，该玻璃纤维可以切断并包装成短切原丝玻璃(chopped strand glass)，以待随后处理用于如以下所描述的湿法(wet-laid)无纺垫中。在一些具体实施方式中，该短切纤维可以具有约0.5-约2.0英寸的长度，或者约1.0-约1.5英寸的长度。在无纺垫中，该短切纤维的长度可以彼此不同。
此外，该纤维可以具有约5微米-约20微米的直径，或者约10微米-约16微米的直径。在无纺垫中该短切纤维的直径可以彼此不同。
已发现，降低纤维的长度和/或直径可以改善由此形成的无纺垫的韧性。韧性的改善可以在相同的基础重量组成下提高界面结合性(存在于更精细的和更短的纤维之间)。界面结合性将有助于应力集中和裂纹扩展的转移，从而获得增强的韧性。然而，尽管精细的纤维可以得到具有更好的抗张强度的、更为封闭的垫子(more closed mats)，但是精细的纤维趋向于引起透气性的减损和树脂渗透的降低。因此，由于拉挤成型应用需要垫子足够开放以便树脂可以渗透，所以需要在形成本文中使用的纤维时获得韧性和透气性的平衡。该纤维可以具有均匀的长度和/或直径，或者该纤维可以具有多种长度和直径，由此满足特定的应用的需要。
所述弹性无纺垫可以通过多种工艺制得，包括干法工艺和湿法工艺。在一些具体实施方式中，所述无纺垫通过湿法工艺形成，其中，包括在添加有多种成分(有时也指白水(white water))例如水、表面活性剂、粘度调节剂(viscosity modifiers)、消泡剂、润滑剂、杀生剂(biocides)和/或其它化学试剂的混合罐中且搅拌下形成分散的纤维的水分散体或浆体，以形成短切玻璃纤维浆体。优选将该浆体充分搅拌以提供均匀的或接近均匀的纤维的分散体。
随后可以根据本领域公知的任意常规方法将所述含水纤维分散体或浆体加工至湿法垫中。例如，将所述含水纤维浆体配置于活动筛(movingscreen)或传送机(conveyor)上，由此大部分的水排出，剩下随机取向的纤维网。该纤维网可以进一步通过真空槽(vacuum slot)或其它干燥装置进行干燥。
随后可以通过常规的方式将粘结剂组合物涂布于纤维网上，例如通过幕涂法(curtain coating)、喷涂法、双线浸浴(twin wire dip bath)、双锟轧机(tworoll padder)及其类似的方法。然后水、多余的粘结剂和多余的偶联剂可以通过真空或其他除水方式而除去。最后，可以在一个或多个烘箱中干燥和固化涂布有粘结剂的纤维产品。干燥的温度范围的实例为约350°F(218℃)-约600°F(304℃)。该干燥和固化后的产品便为完成好的无纺弹性垫。
根据本发明的多种方面，所述粘结剂组合物将配制为这样的组合物，即一旦将该粘结剂固化，便能够给予非常好的机械强度(总抗张强度至少为80lb)、弹性(格利刚度低于5000mgf)和溶剂耐受性(苯乙烯保留量至少为60％)。
在一些具体实施方式中，所述粘结剂组合物含有粘结剂树脂材料、偶联剂和一种或多种任选的添加剂。所述粘结剂树脂可以为热固性材料、热塑性材料或热固性材料和热塑性材料的混合物。所述热固性材料例如可以包括丙烯酸材料、脲醛材料或这两种材料的组合。在一些具体实施方式中，所述丙烯酸材料为聚丙烯酸，例如分子量为10000以下的低分子量聚丙烯酸。所述热固性材料，一旦在合适的固化条件下交联，将提供好的拉伸性能和溶剂耐受性，有助于维持不同应用下的垫子的完整性。在一些具体实施方式中，所述热塑性材料可以包括任何具有低Tg(即低于-15℃)的热塑性材料，例如乙烯醋酸乙烯酯(“EVA”)。在一些具体实施方式中，EVA包括Dur-O-E-646。所述热塑性材料为自交联的(self cross-linking)，且可以提供弹性垫所需的柔软度。
已发现，将粘结剂组合物配成含有具有不同功能(例如热固性的和热塑性的)的树脂可以为纤维增强垫提供改善的性能。特别是，这样的性能的组合可以使得无纺垫用于各种挑战性的应用中，例如在拉挤成型应用中，以替换连续丝垫。一些具体的粘结剂组合物含有约0-约50重量％的热固性材料(例如聚丙烯酸)和约50-约100重量％的热塑性材料(例如EVA)。在其他具体实施方式中，所述粘结剂组合物含有约15-约30重量％的聚丙烯酸和约70-约85重量％的EVA。
在一些具体实施方式中，所述粘结剂树脂可以以约90-约99重量％的含量存在于所述粘结剂组合物中(以所述粘结剂组合物的总重量为基准)，以及在一些具体实施方式中，该含量为约97-约99重量％。本文中“重量％”和“以组合物重量为基准的重量％”是指相对于组合物的总的成分的重量的百分比。
所述粘结剂组合物还可以含有偶联剂。应当理解的是本文中描述的偶联剂本质上用于举例，并且本领域技术人员公知的任何合适的偶联剂都可以用于本文中所描述的或提出的任何具体实施方式中。在一些实施方式中，所述偶联剂可以以约0.05-约10.0重量％的含量存在于所述粘结剂组合物中(以所述粘结剂组合物的总重量为基准)，以及在其他具体实施方式中，以约0.1-约3.0重量％的含量存在。多种具体实施方式包括约0.2重量％的偶联剂。所述偶联剂，除了可以偶联增强纤维的表面和周围的基质以外，其还可以在随后的处理过程中起到降低起毛(fuzz)或破坏纤维丝的水平的作用。
在一些具体实施方式中，至少一种偶联剂为硅烷偶联剂。合适的硅烷偶联剂可以包括含一个或多个氮原子的硅烷，该硅烷可以具有一个或多个官能团例如胺(伯胺、仲胺、叔胺和季铵)、氨基、亚氨基、酰胺基、亚酰胺基、脲基(ureido)或异氰酸基(isocyanato)。合适的硅烷偶联剂还可以包括但不限于氨基硅烷(aminosilanes)、硅烷酯(silane esters)、乙烯基硅烷(vinylsilanes)、甲基丙烯酰氧基硅烷(methacryloxy silanes)、环氧硅烷(epoxysilanes)、硫化硅烷(sulfur silanes)、脲基硅烷(ureido silanes)和异氰酸基硅烷(isocyanato silanes)。本发明中采用的硅烷偶联剂的非限定性的具体实例包括γ-甲基丙烯酰氧基丙基-三甲氧基硅烷(γ-methacryloxypropyl-trimethoxysilane(A-174))、γ-氨基丙基三乙氧基硅烷(γ-aminopropyltriethoxysilane(A-1100))、n-苯基-γ-氨基丙基三甲氧基硅烷(n-phenyl-γ-aminopropyltrimethoxysilane(Y-9669))、n-三甲氧基-甲硅烷基-丙基-乙烯基-二胺(n-trimethoxy-silyl-propyl-ethylene-diamine(A-1120))、甲基-三氯硅烷(methyl-trichlorosilane(A-154))、γ-氯丙基-三甲氧基硅烷(γ-chloropropyl-trimethoxy-silane(A-143))、乙烯基-三乙酰氧基硅烷(vinyl-triacetoxysilane(A-188))和甲基三甲氧基硅烷(methyltrimethoxysilane(A-1630))。
所述粘结剂组合物可以任选地含有其他成分，例如，染料、油、填料、着色剂、水分散体(aqueous dispersions)、UV稳定剂、润滑剂、润湿剂、表面活性剂、粘度调节剂和/或抗静电剂。所述水分散体可以包括抗氧化剂分散体(antioxidant dispersions)，其可阻止粘结剂组合物在老化过程中的氧化作用。抗氧化剂分散体的一个实例包括购自Akron Dispersions,Inc.的Bostex537。所述抗氧化剂分散体的含量可以为0-约5重量％，或者约.5-约3重量％。一些具体实施方式包括约1.8重量％的抗氧化剂分散体。在粘结剂组合物中的添加剂的含量可以为约0.0重量％-约10重量％(以所述粘结剂组合物的重量为基准)。
根据一些具体实施方式，所述粘结剂组合物还含有水以溶解或分散涂布于增强纤维上的成分。水可以加入充足的量以将含水粘结剂组合物稀释至适于将其涂布于增强纤维上的粘度。例如，所述粘结剂组合物可以含有约50重量％-约75重量％的水(以所述粘结剂组合物的重量为基准)。
本发明的结合的垫子可以具有约25-75毫米的平均厚度，或者约30-约60毫米。
将软的但却强的粘结剂组合物以及玻璃纤维和/或合成纤维的合适的混合物进行合并，将制得具有改善的加工能力的弹性无纺垫，其能促进在拉挤成型工艺中的应用，促进平滑的石膏垫的形成，以及促进此前不合适的无纺垫在其他应用的进行。一旦粘结剂固化，便可给予额外的特性，例如改善的机械强度(例如轴向和横向抗张强度)、弹性和溶剂耐受性。
在一些具体实施方式中，弹性无纺垫在轴向上具有至少30lb的平均抗张强度以及在横向上具有至少20lb的平均抗张强度。在一些具体实施方式中，所述弹性无纺垫具有至少50lb的轴向抗张强度以及至少30lb的横向抗张强度。所述弹性无纺垫还可以具有至少50lg或至少80lb的总抗张强度(轴向+横向)。
如上所述的，所述无纺垫具有改善的弹性，其可以采用格利刚度测试仪(Gurley stiffness tester)进行测量。在一些具体实施方式中，所述无纺垫具有约2000-约7000mgf的格利刚度，或者约2500-约6000mgf的格利刚度，以及在其他具体实施方式中，小于5000mgf。
所述弹性无纺垫可以用于多种下游工艺中以制得多种终端产品。在一些具体实施方式中，所述弹性无纺垫可通过拉挤成型工艺用于形成复合材料产品(composite product)。在一些具体实施方式中，所述拉挤成型工艺包括将粗纱和至少一种无纺垫喂入热固性树脂浴(thermosetting resin bath)中，其中将粗纱移至涂布棒(spreader bars)上方以此助于树脂浸渍于纤维中。所述粗纱可以由玻璃纤维、石墨纤维、硼纤维、聚芳香聚酰胺纤维(polyaramidfibers)或其它相似的纤维制得。优选地，所述粗纱由玻璃纤维制得。
一旦所述粗纱充分地浸渍有树脂，在进入热成型模(heated molding die)之前，将存在于树脂浴中的粗纱和无纺垫通过预成型机(pre-former)预成型为一定形状或具有一定轮廓。然后将具有预成型形状的粗纱和无纺垫在通过热成型模时连续加热以固化为所需形式的复合材料。一对履带式辊(caterpillar rollers)可以用于将粗纱和无纺垫送入浴、预成型机和/或热模中。随后存在于热模中的复合材料部件将通过切割装置切断成所需长度。在该方式中，连续粗纱的纤维浸渍有聚合物树脂，垫子涂布有聚合物树脂，纤维和垫子成型为了复合材料的形式，并切断以形成拉挤成型部件。所述粗纱为该拉挤成型部件提供了纵向上的抗张强度，所述无纺垫为该拉挤成型部件提供了横向上的抗张强度。
如本文中所描述的，所述粘结剂组合物提供了改善的苯乙烯单体耐受性(苯乙烯单体常见于用于拉挤成型工艺中的热固性树脂中)。该提高的苯乙烯单体耐受性能够使得本发明的弹性垫更适合于拉挤成型工艺。如本文中所描述的，苯乙烯单体是一种强溶剂，其可以溶胀并降解粘结剂，从而弱化垫子的连续性。通过为弹性无纺垫提供苯乙烯单体耐受性，所述弹性无纺垫，以及由此所得的引入有该弹性无纺垫的拉挤成型部件，可以在纵向上以及横向上维持抗张强度。
所述弹性无纺垫还可以用于其他工艺，例如，常用于建筑领域的石膏墙板和/或石膏面板的生产。将石膏芯夹在面层(facing layers)之间而形成的墙板常用于建筑业以作为住宅楼和商业楼的内墙(internal walls)和天花板。石膏芯通常含有石膏，任选含有一些湿的短切玻璃纤维、耐水化学品、粘结剂、促进剂(accelerants)和低密度填料。本领域公知的是为了制备石膏板，可通过提供连续的面材(facing material)层(例如纤维面纱)并将石膏浆体配置于该面材的一面上。然后将第二连续的面材层施用于该石膏浆体的相对面。在这种方式下，石膏浆体将夹在相对的面材层之间。随后调节该夹着的石膏浆体至所需厚度并干燥以强化该石膏芯从而形成石膏板。然后，可以将该石膏板切成预定的尺寸(例如长度)以便最终使用。玻璃纤维常用于制备石膏墙板以改善所得产品的抗张强度和撕裂强度(tear strength)。
根据多种具体实施方式，所述弹性无纺垫可以用作石膏墙板的面层，相对于表面为纸或其它纤维素面材(cellulosic facing materials)的传统石膏板来说，其能提供在潮湿环境下提高的尺寸稳定性、提高的生物耐受性(biological resistance)、提高的透气性以及增强的物理和机械性能，例如更高的强度和耐久性。
以上通过公开多种实施方式对本发明的大体构思进行了大致的介绍，以下将通过参照下面所列的具体实施例来进一步说明，这些实施例仅以说明为目的，并不意在总括或限定本发明。
实施例
为了更为彻底地描述本发明，提供了以下实施例。
实施例1
通过传统的湿法涂布工艺制备了三种无纺垫，其中，短切玻璃纤维以含水浆体的形式在配置于活动筛上后，涂布粘结剂组合物的水分散体，然后干燥和固化。每个垫子都是采用具有同样的烧失量(loss on ignition，LOI)和基重(base weight)的1.25”M纤维(16微米的直径)制成的。每个垫子上涂布的粘结剂组合物含有多种比例的热塑性/热固性成分。第一号垫子的粘结剂含有100％的聚丙烯酸，第二号垫子的粘结剂含有75％的聚丙烯酸和25％的乙烯醋酸乙烯酯，以及第三号垫子的粘结剂含有50％的聚丙烯酸和50％的乙烯醋酸乙烯酯。每种组合物都在485°F下固化。
然后测量由此获得的玻璃纤维垫的最大弯曲强度和格利刚度，以此确定该垫子的耐弯曲性/刚性。
结果如表1所示。
表1
垫子弹性vs.粘结剂组合物比例
如表1所示，随着粘结剂组合物中EVA的用量的升高，无纺垫的弹性也随之改善。例如，粘结剂配方中含有25重量％的EVA时，弹性垫可以获得低于7000mgf的格利刚度，在粘结剂组合物中含有50重量％的EVA时，无纺垫可以获得低于5000mgf的格利刚度。
尽管本文中仅描述的本发明的一些实施方式，但是应当理解的是在不背离本发明的精神和范围下可以进行许多的改变。所有这样的改变都应当包括在本发明和对应的整体构思范围内，该范围仅由附带的权利要求所限定。

Claims (28)

1.一种无纺垫，该无纺垫含有：
约10-约100重量％的短切玻璃纤维；
约0-约90重量％的合成纤维；以及
2.含有热固性材料和热塑性材料的混合物以及偶联剂的粘结剂组合物，其中，所述无纺垫具有提高的弹性和抗张强度。
3.根据权利要求1所述的无纺垫，其中，所述无纺垫含有约50-约90重量％的短切玻璃纤维和约10-50重量％的合成纤维。
4.根据权利要求1或2所述的无纺垫，其中，所述短切玻璃纤维与所述合成纤维相混合。
5.根据权利要求1-3中任意一项所述的无纺垫，其中，所述合成纤维包括聚丙烯、聚酯及其组合中的至少一种。
6.根据权利要求1-4中任意一项所述的无纺垫，其中，所述短切玻璃纤维具有约0.25-约2.0英寸的长度。
7.根据权利要求1-5中任意一项所述的无纺垫，其中，所述合成纤维为具有约0.5-约2.0英寸的长度的短切纤维。
8.根据权利要求1-6中任意一项所述的无纺垫，其中，所述短切玻璃纤维具有约5-20微米的直径。
9.根据权利要求1-7中任意一项所述的无纺垫，其中，所述合成纤维具有约10-16微米的直径。
10.根据权利要求1-8中任意一项所述的无纺垫，其中，所述偶联剂为硅烷偶联剂。
11.根据权利要求1所述的无纺垫，其中，所述热固性材料包括丙烯酸材料、脲醛材料中的至少一种或二者的组合。
12.根据权利要求1所述的无纺垫，其中，所述热塑性材料包括乙烯醋酸乙烯酯。
13.根据权利要求1所述的无纺垫，其中，所述粘结剂树脂含有约50-约100重量％的热塑性材料和约0-约50重量％的热固性材料。
14.根据权利要求13所述的无纺垫，其中，所述粘结剂树脂含有约70-约90重量％的热塑性材料和约0-约50重量％的热固性材料。
15.根据权利要求10-14中任意一项所述的无纺垫，其中，所述粘结剂组合物中的所述偶联剂的含量为约0.05-约10重量％。
16.根据权利要求1-15中任意一项所述的无纺垫，其中，所述粘结剂组合物还含有染料、油、填料、着色剂、水分散体、UV稳定剂、润滑剂、润湿剂、表面活性剂和抗静电剂中的至少一种。
17.根据权利要求16所述的无纺垫，其中，所述水分散体为抗氧化剂分散体。
18.根据权利要求1-17中任意一项所述的无纺垫，其中，所述粘结剂组合物耐受苯乙烯单体。
19.根据权利要求1-18中任意一项所述的无纺垫，其中，该无纺垫在轴向上具有至少30lb的平均抗张强度，以及在横向上具有至少20lb的平均抗张强度。
20.根据权利要求1-19中任意一项所述的无纺垫，其中，该无纺垫具有约2000-约6000mgf的格利刚度。
21.一种拉挤成型复合材料产品，该产品包括：
至少一种浸渍有热固性树脂的粗纱；以及
无纺垫，该无纺垫含有：
约10-约95重量％的短切玻璃纤维；
约5-约90重量％的合成纤维；和
含有热固性材料和热塑性材料的混合物以及偶联剂的粘结剂组合物，其中，所述无纺垫具有提高的弹性和抗张强度。
22.根据权利要求21所述的拉挤成型复合材料产品，其中，所述无纺垫含有约50-约90重量％的短切玻璃纤维和约10-50重量％的合成纤维。
23.根据权利要求21和22中任意一项所述的拉挤成型复合材料产品，其中，偶联剂包括硅烷偶联剂。
24.根据权利要求21所述的拉挤成型复合材料产品，其中，所述热固性材料包括丙烯酸材料、脲醛材料中的至少一种或二者的组合。
25.根据权利要求21-24中任意一项所述的拉挤成型复合材料产品，其中，所述热塑性材料包括乙烯醋酸乙烯酯。
26.根据权利要求21-25中任意一项所述的拉挤成型复合材料产品，其中，所述无纺垫在轴向上具有至少30lb的平均抗张强度，以及在横向上具有至少20lb的平均抗张强度。
27.根据权利要求21-26中任意一项所述的拉挤成型复合材料产品，其中，所述无纺垫具有约2000-约6000mgf的格利刚度。
28.一种石膏墙板，该石膏墙板包括：
石膏芯；以及
与所述石膏芯结合的至少一种无纺垫，所述无纺垫含有：
约10-约95重量％的短切玻璃纤维；
约5-约90重量％的合成纤维；和
含有热固性材料和热塑性材料的混合物以及偶联剂的粘结剂组合物，其中，所述无纺垫具有提高的弹性和抗张强度。
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EP3058126B1 (en) 2017-09-06
US20160273140A1 (en) 2016-09-22
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KR102233322B1 (ko) 2021-03-26
CA2927534C (en) 2022-10-04
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EP3058126A1 (en) 2016-08-24
JP2016533438A (ja) 2016-10-27
CA2927534A1 (en) 2015-04-23
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WO2015057763A1 (en) 2015-04-23
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