CN106794660A - 丛丝片材 - Google Patents
丛丝片材 Download PDFInfo
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- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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- D04H3/16—Non-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 filaments produced in association with filament formation, e.g. immediately following extrusion
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Abstract
本发明公开了一种具有丛丝结构的片材,所述片材具有介于0.002(m3/m2.分钟)@ 50gsm和0.2(m3/m2.分钟)@ 50gsm之间的标称弗雷泽透气率,和介于150厘米@ 50gsm和250厘米@ 50gsm之间的标称静压头。
Description
技术领域
本发明涉及适用于房屋包裹物、防护服装、和其中片材或织物必须展示出良好的阻隔特性和低透气性的其它最终用途的闪纺丛丝片材或织物。
背景技术
房屋包裹物用于在其构造期间并且更具体地讲在附接护套之后和安装壁板/包层之前,包裹房屋或其它建筑的外表面。
房屋包裹物通常包括阻隔层,其提供对外部水或湿气的防潮层,但是允许水蒸气从房屋的内部透过。以这种方式,限制了液体水和空气(例如,雨和风)进入建筑结构的通道,从而防止水对绝缘物和结构构件的损坏,并使壁内的空气运动最小化。同时,从建筑结构的内部进入壁中的水蒸气可离开,使得其不在壁内凝结并潜在损坏绝缘物和结构构件。典型的房屋包裹物阻隔材料包括纺粘高密度聚乙烯纤维,其以商品名“DuPont™ Tyvek®HomeWrap®”由E.I. Du Pont de Nemours and Company(Wilmington,DE)出售;非织造阻隔材料,其以商品名“DuPont™ Tyvek® CommercialWrap®”由E.I. Du Pont de Nemours andCompany(Wilmington,DE)出售;高密度交联层合微穿孔聚乙烯片材料,其以商品名“Rufco-wrap”由Raven Industries, Inc.(Sioux Falls,SD)出售;以及交联织造微穿孔聚烯烃片材料,其分别由Amoco Foam Products Company(Atlanta,GA.)和Fabrene Inc.(Mississauga,Ontario,Canada)以商品名“Amowrap Housewrap”和“Air-Gard®Housewrap”出售。
房屋包裹物需要低弗雷泽透气率,但仍然具有高静压头。因此,需要提供保护性包裹物,其改善能量效率并且防止建筑中的空气渗入和湿气聚集,同时满足新实施的全行业能源和建筑规范法规。还需要采用保护性包裹物,其满足或超过对于现有框架结构或开口的新实施的规范要求和/或不增加建筑的壁轮廓。
发明内容
本发明涉及一种片材,其具有介于0.002m3/m2.分钟@ 50克/平方米和0.2m3/m2.分钟@ 50克/平方米(gsm)之间的标称弗雷泽透气率,和介于150cm @ 50gsm和250cm @ 50gsm之间的标称静压头。
本发明的另一个实施方案具有至少9m2/g的BET表面积。
在另一个实施方案中,所述片材具有小于或等于0.09m3/m2.分钟@ 50gsm的标称弗雷泽透气率。所述片材还具有大于或等于0.0075m3/m2.分钟@ 50gsm的标称弗雷泽透气率。
在另一个实施方案中,所述片材具有介于165cm @ 50gsm和208cm @ 50gsm之间的标称静压头。
在另一个实施方案中,所述片材具有介于9m2/g和25m2/g之间的BET表面积,或甚至介于9m2/g和20m2/g之间的BET表面积。
所述片材还可具有大于或等于30克/平方米的基重。
本发明还涉及多层结构,其包括大量两种或更多种片材,其中至少一个片材为包括丛丝结构的片材,其具有介于0.002m3/m2.分钟@ 50gsm和0.2m3/m2.分钟@ 50gsm之间的标称弗雷泽透气率,
I.介于150cm @ 50gsm和250cm @ 50gsm之间的标称静压头,以及
ii.大于或等于30gsm的基重。
本发明的多层结构的另一个实施方案具有至少9m2/g的BET表面积。
附图说明
图1示出例示了用于制备闪纺丛丝片材的方法的纺丝单元的示意性、未按比例绘制的剖视图。
具体实施方式
本发明申请人特别地将所有引用的参考文献的完整内容引入本公开中。此外,当量、浓度或其它值或参数以范围、优选范围或优选上限数值和优选下限数值的列表形式给出时,其应被理解为具体地公开由任何范围上限或优选数值和任何范围下限或优选数值中的任何一对所构成的所有范围,而不管这些范围是否被单独地公开。凡在本文中给出某一数值范围之处,该范围均旨在包含其端点以及在该范围内的所有整数和分数,除非另行指出。不旨在将本发明的范围限制为限定范围时所引用的具体数值。
如本文所用,术语“聚合物”通常包括但不限于均聚物、共聚物(诸如例如嵌段、接枝、无规和交替共聚物)、三元共聚物等,以及它们的共混物和修饰形式。此外,除非另外具体限定,术语“聚合物”应包括所述材料所有可能的几何构型。这些构型包括但不限于全同立构、间同立构、以及无规对称。
如本文所用,术语“聚乙烯”旨在不仅涵盖乙烯的均聚物,而且涵盖其中至少85%的重复单元为乙烯单元的共聚物。
如本文所用,术语“非织造物”、“非织造片材”或“非织造纤维”表示以无规方式定位以形成平面材料而没有如针织物中可辨别的图案的单个纤维或线的结构。
如本文所用,“纵向”是片材的平面内的长方向,即,其中制备片材的方向。“横向”是片材平面内的垂直于纵向的方向。
如本文所用,术语“丛丝”是指多个无规长度的细的、带状、膜-原纤元件的三维整体网络,并且具有小于约25微米的中值原纤宽度。在丛丝结构中,膜-原纤元件一般与该结构的纵向轴线共延对准,并且它们以不规则的间隔在该结构的遍及长度、宽度和厚度的多个位置中间歇联合和分离以形成连续的三维网络。
术语“纺丝流体”是指使用本文所述的纺丝设备纺丝的总体组合物。纺丝流体包含聚合物和纺丝剂。
术语“纺丝剂”是指用于初始溶解聚合物以形成纺丝流体的加工介质或介质的混合物。
所谓“基本上由……形成”是指受权利要求书保护的物体,其包含主要组分,但可包含添加以改善或改性受权利要求保护的物体的功能特性的其它物体。例如,基本上由聚乙烯组成的物体还可包含填料、抗氧化剂和改性其性能或功能的其它添加剂。
测试方法
在说明书、实施例和权利要求中,采用以下测试方法来测定各种报道的特征及特性。ASTM是指美国测试与材料协会,TAPPI是指纸浆和造纸工业技术协会。
丛丝膜-原纤纤维网产品的BET表面积是闪纺产品的原纤化程度和细度的另一量度。表面积通过S. Brunauer、P. H. Emmett和E. Teller、J. Am. Chem.Soc.,第60卷,第309-319页(1938)的BET氮吸收方法测量,并以m2/g为单位记录。BET表面积使用Quantachrome型号NOVA 3000e来测量。
基重通过ASTM D-3776(其以引用方式并入)来测定,并以g/m2或gsm为单位记录。下文实施例所记录的基重各自基于对样品进行的至少十二次测量的平均值。
Gurley Hill(或仅“Gurley”)孔隙率是片材料对气态物质的渗透性的量度。具体地讲,其是一定体积的气体通过其中存在一定压力梯度的材料区域所需时间的量度。Gurley Hill孔隙率根据TAPPI T-460 OM-88使用Lorentzen & Wettre Model 121D密度计测量。该测试测量100立方厘米空气在约1.21kPa(4.9英寸)的水压下被推过28.7mm直径样品(具有一平方英寸的面积)所需的时间。结果以秒为单位表示,其通常称为格雷秒。
弗雷泽透气率为多孔材料透气率的量度并以单位ft3/min/ft2记录。弗雷泽透气率根据ASTM D737-04来测量。其测量在0.5英寸水柱(等于124.5Pa)的压差下通过材料的气流体积。将喷丝孔安装在真空系统中以将空气的通过样本的流量限制到可测量的量。喷丝孔尺寸取决于材料的孔隙率。使用具有校准喷丝孔单元的Sherman W.Frazier Co.双压力计测量弗雷泽透气率(也称为弗雷泽孔隙率),其以ft3/(ft2 min)为单位,出于在本文记录的目的,将其转换为m3/(m2 min)。本文记录的弗雷泽透气率归一化为50克/平方米(gsm)的基重。如果仅对样品测量Gurley空气孔隙率,则弗雷泽透气率根据以下公式计算:
弗雷泽透气率(m3/m2 min)× Gurley空气孔隙率(秒)= 0.945。
为有利于比较不同基重的片材的弗雷泽透气率,方便的是将弗雷泽透气率对具有50克/平方米基重的片材进行归一化。对于50克/平方米的基重的标称弗雷泽透气率测定为以下关系:
。
静水压头(或静压头)为所述片在静态载荷下抵抗液态水渗透的阻力的量度。将一个7英寸×7英寸(17.78cm×17.78cm)样本安装在SDL 18 Shirley Hydrostatic HeadTester(由Shirley Developments Limited,Stockport,England制造)中。以60+/-3cm/min的速率,将水泵送压向样品的102.6cm部分的一个侧面,所述样品由具有约0.28mm直径的线的30目网格支撑,直至样品的三个区域被水渗透。静水压力按英寸测量,转换成SI单位并以厘米静水头给出。所述测试一般遵从ASTM D 583(从1976年11月的公布提取)。
本文中静压头如根据以下公式归一化为50克/平方米的基重来记录:
。
本发明的实施方案
本发明涉及一种包括丛丝结构的片材,所述片材具有介于0.002m3/m2.分钟@ 50gsm和0.2m3/m2.分钟@ 50gsm之间的标称弗雷泽透气率,和就50克/平方米的基重而言,介于150cm@ 50gsm和250cm @ 50gsm之间的标称静压头。术语“@ 50gsm”是指上文给出的归一化程序,其中任何任意基重的测量值归一化为50gsm。
在另一个实施方案中,片材基本上由聚乙烯组成。
在另一个实施方案中,片材的BET表面积为至少9m2/g。
在另一个实施方案中,所述片材具有小于或等于0.09 m3/(m2.分钟)@ 50gsm的标称弗雷泽透气率。所述片材还具有大于或等于0.0075m3/m2.分钟@ 50gsm的标称弗雷泽透气率。
在另一个实施方案中,所述片材具有介于165cm @ 50gsm和208cm @ 50gsm之间的标称静压头。
在另一个实施方案中,所述片材具有介于9m2/g和25m2/g之间的BET表面积,或甚至介于9m2/g和20m2/g之间的BET表面积。
所述片材还可具有大于或等于30克/平方米的基重。
在另一个实施方案中,根据本文所述的实施方案中任一项所述的闪纺丛丝纤维股线可以固结成片材结构。然后可将该片材结构任选地热粘结或机械粘结。
本发明还涉及多层结构,其包括大量的两种或更多种片材,其中至少一种片材为包括丛丝结构的聚乙烯片材,其具有:
I. 介于0.002m3/m2.分钟@ 50gsm和0.2m3/m2.分钟@ 50gsm的标称弗雷泽透气率,
ii. 介于150cm @ 50gsm和250cm @ 50gsm之间的标称静压头,以及
III. 大于或等于30克/平方米(gsm)的基重。
本发明的多层结构的另一个实施方案包括具有至少9m2/g的BET表面积的丛丝片材。
用于制备闪纺丛丝片材,并且具体地讲Tyvek®纺粘烯烃片材料的方法,首先描述于授予Blades等人的美国专利3,081,519中。(转让给DuPont.)'519专利描述了一种方法,其中在高于液体的标称沸点的温度下并且在自生压力或更大下,将聚合物的液体纺丝剂溶液(所述液体纺丝剂在低于液体的标称沸点时不是聚合物的溶剂)纺成较低温度和显著较低压力的区域,以产生丛丝膜-原纤股线。如授予Anderson等人的美国专利3,227,794中所公开的(转让给DuPont),当聚合物和纺丝剂溶液的压力在即将闪纺之前在减压室中略微降低时,使用Blades等人中公开的方法最佳获得从丝膜-原纤股线。
对本发明例示选择的一般闪纺设备类似于授予Brethauer等人的美国专利3,860,369中所公开的设备,所述文献以引用方式并入本文。用于闪纺纤维形成聚合物的系统和方法完全公开于美国专利3,860,369中,并示于图1中。闪纺工艺通常在室10中进行,该室有时被称为纺丝单元,其具有纺丝剂移除端口11和用以将过程中形成的非织造片材料移除的开口12。通过加压供应管道13将包含聚合物和纺丝剂的混合物的纺丝流体提供给纺丝喷丝孔14。纺丝流体从供应管13通过室开口15到室16。在某些纺丝应用中,室16可用作减压室,其中压力减小导致纺丝流体的相分离,如授予Anderson等人的美国专利3,227,794中所公开的。可提供压力传感器22以监测室16中的压力。
接着室16中的纺丝流体穿过纺丝喷丝孔14。据信加压聚合物和纺丝剂从室16进入纺丝喷丝孔中的通道形成靠近喷丝孔附近的拉伸流体,其有助于取向聚合物。当聚合物和纺丝剂从喷丝孔释放时,纺丝剂快速膨胀为气体并留下原纤化丛丝膜-原纤。气体通过端口11离开室10。优选地,将气态纺丝剂冷凝以重新用于纺丝流体。
从纺丝喷丝孔14释放的聚合物股线20通常针对旋转的偏转器挡板26定向。旋转挡板26将股线20展开成更加平面的结构24,使得挡板交替指向左和右。当展开的纤维股线从挡板下降时,纤维股线被静电充电,以便使纤维股线以展开的构型保持直至纤维股线24到达移动带32。纤维股线24沉积在带32上以形成片材34。将带接地以有助于确保带电纤维股线24在带上的适当定位。纤维片34可以在辊31下通过,所述辊将片材压缩成略固结的片材35,其由以重叠的多取向构造取向的丛丝膜-原纤网络形成。所述片材35通过出口12离开纺丝室10,然后在片材收集辊29上收集。
“热固结”或“热粘结”片材是通过本发明纤维网的热固结制成的片材。热粘结方法的一些示例为通过气体粘结、蒸汽缠结、超声波粘结、拉伸粘结、热压延、热辊压花、热表面粘结。
热表面粘结可通过如授予David的美国专利3,532,589对于硬粘结表面所述的方法来进行。在该方法中,丛丝片材随后通过加热鼓-冷却鼓-加热鼓-冷却鼓上方以热粘结材料的两个侧面。将加热鼓保持在可导致丛丝结构部分熔融的温度下,以包括片材的粘结。冷却鼓具有将温度降低至一定值的目的,其中当不受约束时片材将不收缩或变形。在粘结过程期间,片材被柔性带轻轻压缩以具有受控收缩。
另选地,丛丝片可借助于压花辊和橡胶涂覆的支撑辊粘结以粘结片材的一个或两个侧面。压花辊可以是平滑的或包含不同图案,例如,但不限于示于以下参考文献中的那些,即,点状图案(US 3,478,141、US 6,610,390、US 2004/241399 A1)、肋状图案(US2003/0032355 A1)、无规图案(US 7,744,989)或不同图案(US 5,964,742)。片材可通过压花辊与橡胶涂覆的支撑辊的一个或多个位点。此外,在压花辊和支撑辊配对之前和之后,片材可与预热辊或冷却辊接触,如US 5,972,147中所述。最终,在粘结过程中,材料可例如通过按钮式结块破碎机软化,如由Dempsey在US 3,427,376中所述。
实施例
根据美国专利号3,860,369和上文所述的方法,制备纺丝流体、闪纺并形成为固结片材。在实施例中记录的聚合物浓度,基于总纺丝流体重量计,计算为聚合物的重量百分比,其中总纺丝流体重量包括聚合物的重量和纺丝剂的重量。
除非另外指明,在本发明实施例中制备的丛丝纤维网和片材使用由81重量百分比二氯甲烷和19重量百分比2,3-二氢十氟戊烷组成的纺丝剂来闪纺。比较例由包含正戊烷的纺丝剂来制备。本发明的片材由闪纺工艺产生,所述闪纺工艺由至少15cm3的上游减压室,和最小75巴表压的释放压力来进行,产生300旦尼尔至400旦尼尔的纤维。
用于所有实施例中的聚合物为高密度聚乙烯,其具有2.35g/10min(根据EN ISO1133,在190℃和5kg负载下测量)和24.5g/10min(根据EN ISO 1133,在190℃和21.6kg负载下测量)的熔体指数,0.96g/cm3的密度(根据EN ISO 1183测量)。用于比较例中的聚合物为高密度聚乙烯,其具有0.96g/10min(根据ASTM D 1238,在190℃和2.16kg负载下测量)和34.4g/10min(根据ASTM D 1238,在190℃和21.6kg负载下测量)的熔体指数。
表1概述了实施例和比较例的纺丝条件。
表1
样品 | 纺丝流体的聚合物浓度重量百分比 | 纺丝压力(barg) | 纺丝流体温度(℃) |
实施例1 | 12 | 85.5 | 195 |
实施例2 | 14 | 76.0 | 190 |
实施例3 | 13 | 83.0 | 190 |
比较例1 | 17 | 76.0 | 192 |
比较例2 | 17 | 81.1 | 194 |
比较例3 | 17 | 85.6 | 198 |
比较例4 | 17 | 90.6 | 200 |
比较例5 | 17 | 90.9 | 201 |
比较例7 | 21.3 | 40.0 | 180 |
比较例8 | 17.1 | 67.9 | 190 |
比较例9 | 17.9 | 59.7 | 185 |
表2概述了获得的闪纺丛丝片材的特性。比较例7至9描述了附加基重值的标称弗雷泽透气率和标称静压头@ 50gsm。不测量BET表面积(n.m.)。
表2
样品 | 基重(gsm) | 标称弗雷泽透气率(m3/m2.分钟@ 50gsm) | 标称静压头(cm @ 50gsm) | BET表面积(m2/g) |
实施例1 | 41.4 | 0.089 | 165 | 9.8 |
实施例2 | 42.3 | 0.0075 | 174 | 18.5 |
实施例3 | 41.0 | 0.016 | 208 | 13.0 |
比较例1 | 61.0 | 0.013 | 104 | 21.6 |
比较例2 | 60.0 | 0.018 | 105 | 19.1 |
比较例3 | 61.7 | 0.04 | 95 | 15.4 |
比较例4 | 60.7 | 0.065 | 100 | 15.4 |
比较例5 | 59.7 | 0.065 | 101 | 13.7 |
比较例7 | 66.5 | 0.0024 | 69.3 | n.m. |
比较例8 | 40.7 | 0.076 | 106.8 | n.m. |
比较例9 | 54.2 | 0.015 | 77.8 | n.m. |
根据表2选择的比较标准,比较例均不实现本发明实施例的静压头性能,本发明的实施例表现出独特的性能组合。
Claims (13)
1. 一种包括丛丝结构的片材,所述片材具有介于0.002m3/m2.分钟@ 50gsm和0.2m3/m2.分钟@ 50gsm之间的标称弗雷泽透气率,和介于150cm @ 50gsm和250cm @ 50gsm之间的标称静压头。
2.根据权利要求1所述的片材,所述片材基本上由聚乙烯组成。
3.根据权利要求1所述的片材,其中所述丛丝结构具有至少9m2/g的BET表面积。
4. 根据权利要求1所述的片材,其中所述丛丝结构具有小于或等于0.09m3/m2.分钟@50gsm的标称弗雷泽透气率。
5. 根据权利要求1所述的片材,其中所述丛丝结构具有大于或等于0.0075m3/m2.分钟@50gsm的标称弗雷泽透气率。
6. 根据权利要求1所述的片材,其中所述丛丝结构具有介于165厘米@ 50gsm和208厘米@ 50gsm之间的标称静压头。
7.根据权利要求6所述的片材,其中所述丛丝结构具有介于9m2/gm和25m2/gm之间的BET表面积。
8.根据权利要求6所述的片材,其中所述丛丝结构具有介于9m2/gm和20m2/gm之间的BET表面积。
9.根据权利要求1所述的片材,其中所述丛丝结构具有大于或等于30克/平方米的基重。
10.一种多层结构,所述多层结构包括大量的两种或更多种片材,其中至少一种片材为根据权利要求1所述的片材。
11.根据权利要求10所述的结构,其中所述丛丝结构具有至少9m2/g的BET表面积。
12.一种热固结片材,所述热固结片材由根据权利要求1所述的片材制成。
13.一种多层结构,所述多层结构包括大量的两种或更多种片材,其中至少一种片材为根据权利要求12所述的片材。
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CN114150439A (zh) * | 2021-11-29 | 2022-03-08 | 厦门当盛新材料有限公司 | 闪蒸纺丝丝束网的牵伸装置及闪蒸纺丝设备 |
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US11866558B2 (en) | 2024-01-09 |
US20150368416A1 (en) | 2015-12-24 |
JP2023052010A (ja) | 2023-04-11 |
CN106794660B (zh) | 2020-12-08 |
JP2017523315A (ja) | 2017-08-17 |
WO2015195898A1 (en) | 2015-12-23 |
EP3158119B1 (en) | 2020-07-22 |
US20210130559A1 (en) | 2021-05-06 |
JP2021055254A (ja) | 2021-04-08 |
EP3158119A1 (en) | 2017-04-26 |
JP6879742B2 (ja) | 2021-06-02 |
CN112549713A (zh) | 2021-03-26 |
US10920028B2 (en) | 2021-02-16 |
CN112549713B (zh) | 2023-12-22 |
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