CN110270472B - 立体织物复合材料的制造方法、涂布机及制得的复合材料 - Google Patents

立体织物复合材料的制造方法、涂布机及制得的复合材料 Download PDF

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CN110270472B
CN110270472B CN201910204442.0A CN201910204442A CN110270472B CN 110270472 B CN110270472 B CN 110270472B CN 201910204442 A CN201910204442 A CN 201910204442A CN 110270472 B CN110270472 B CN 110270472B
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coating
base material
composite material
coating film
dimensional fabric
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CN110270472A (zh
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芮祥鹏
江慧宜
周子伟
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Tsm Smart Materials Co ltd
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    • D06B1/10—Applying liquids, gases or vapours onto textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing or impregnating by contact with a member carrying the treating material
    • D06B1/14—Applying liquids, gases or vapours onto textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing or impregnating by contact with a member carrying the treating material with a roller
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Abstract

本发明提供一种立体织物复合材料的制造方法、涂布机及制得的复合材料。所述制造方法是具有网孔的立体织物作为基材，制造所述基材表面具有涂层的立体织物复合材料的方法，包括以下步骤：提供一树脂组成物；涂布步骤；以及开孔步骤。所述涂布机是用于在具有网孔的基材上形成有孔涂膜的涂布装置，包括：涂布装置；传动滚轮；开孔装置。所述复合材料是利用所述的方法制造而得或使用所述的涂布机制造而得。

Description

立体织物复合材料的制造方法、涂布机及制得的复合材料
技术领域
本发明涉及一种立体织物复合材料的制造方法，特别涉及一种立体织物复合材料的制造方法、涂布机以及使用该方法得到的复合材料。
背景技术
立体织物或网布(3-D fabric或spacer fabric)，具有结构强韧富弹性且因多孔而质轻的特点，在各个层面的应用，正持续被开发中，例如服饰、鞋材、交通运输、建筑、农用及医疗等创新应用。于本说明书，所谓立体织物复合材料，是指立体织物的全部表面或一部分表面，具有涂层的复合材料。上述涂层可由各种无机或有机化合物、聚合物、共聚物、树脂等所构成，只要是可赋予立体织物不同于周围无涂层的区域不同的指定的物理及/或化学特性。在立体织物表面附加涂层，可赋予立体织物特殊的功能，通过只在立体织物的特定区域赋予涂层，可在特定区域具有与周围无涂层的区域不同的物理及/或化学特性，例如国际公开专利WO2006/079602记载的结合热塑性材料与立体织物作为骨折固定装置、美国专利第6482167号记载的骨科铸造技术等，因为立体织物具有透气性佳及质轻的特性，再加上热塑性材料的机械强度及可塑性，非常适合取代传统石膏作为骨折的固定夹板或支持板。
然而，在制作立体织物复合材料时，一般使用涂布或含浸法，然而使用含浸法制作立体织物复合材料时，通常是使用构成涂层的材料溶解于溶剂的溶液，将立体织物浸渍于所述溶液中，再移除溶剂，而得到立体织物复合材料。如此的制造方法，需要使用溶剂，且除去溶剂时需耗费大量能源，除制造的安全性不佳外，制造成本高且对环境不友善。另一方面，使用涂布法制作立体织物复合材料时，通常的涂布法所使用的涂料为了促进浸润于立体织物中，也有包含溶剂的情况，而且因通常的涂布法所制作的涂膜，皆为完整涂膜，因为立体织物所具有的网孔填满涂料，导致立体织物失去透气性。然而，立体织物复合材料具有透气的性质，在许多应用上是必要的特征，所以如何制造立体织物复合材料，使立体织物复合材料具有透气性，成为产业亟需的技术。
发明内容
鉴于上述的发明背景，为了符合产业上的要求，本发明的目的之一在于提供一种立体织物复合材料的制造方法，通过连续涂膜于立体织物表面后实施开孔步骤，除可制造具有透气性的立体织物复合材料外，降低生产成本，提高生产效率。
再者，本发明的目的之一在于提供一种涂布机，通过使用滚轮对滚轮的涂布方式，收卷时使用滚轮时可连续地制造膜状的立体织物复合材料，直接裁切切时可连续地制造板状的立体织物复合材料。
为了达到上述目的，根据本发明一实施态样，提供一种立体织物复合材料的制造方法，其是具有网孔的立体织物作为基材，制造所述基材表面具有涂层的立体织物复合材料的方法，包括以下步骤：提供一树脂组成物；将所述树脂组成物，通过一涂布机构，形成涂膜于所述基材的一侧或两侧的表面，得到一表面具有涂膜的基材的涂布步骤；以及将所述表面具有涂膜的基材，通过一开孔机构，破坏涂膜在网孔间的弯液面(meniscus)，得到表面开孔的立体织物复合材料的开孔步骤。
再者，根据本发明另一实施态样，提供一种涂布机，其是用于在具有网孔的基材上形成有孔涂膜的涂布装置，包括：将构成涂膜的材料成为流体的涂布装置，用以在基材表面形成涂膜；多个传动滚轮，连续传递长条状的基材；开孔装置，使通过所述开孔装置的基材形成连通基材的两表面的贯穿孔，使所述基材具有透气性。
再者，根据本发明另一实施态样，提供一种立体织物复合材料，其是通过使用上述本发明的立体织物复合材料的制造方法或上述本发明的涂布机制造而得。
根据本发明的立体织物复合材料的制造方法及/或涂布机，可连续地制造具有透气性的立体织物复合材料外，降低生产成本，提高生产效率。根据本发明的立体织物复合材料的制造方法及/或涂布机所制造的立体织物复合材料，可具有质轻、透气性佳、追随性佳、操作性佳等的优点，依据复合材料的特性，可应用于例如服饰、鞋材、交通运输、建筑、农用及医疗等的各种领域。
附图说明
图1是表示根据本发明的立体织物复合材料的制造方法的流程图。
图2是表示关于本发明的立体织物复合材料的剖面图。
图3是表示图2所示的关于本发明的立体织物复合材料的上视图。
图4是表示根据本发明的涂布机的一例的示意图。
图5是表示根据本发明的涂布机构或涂布装置的一例的示意图。
图6是表示根据本发明的涂布机构或涂布装置的一例的示意图。
图7是表示根据本发明的涂布机构或涂布装置的一例的示意图。
图8是表示根据本发明的开孔机构或开孔装置的一例的示意图。
主要附图标号说明：
1立体织物复合材料，10a、10b外部层，20中间层，30立体织物，40涂层，100涂布机，110前处理装置，105a、105b、105c传送滚轮，120a、120b模头，125a、125b涂布滚轮，140a、140b压入滚轮，130热滚轮，150开孔装置，160冷却装置，170切割机，180a、180b压入及涂布滚轮。
具体实施方式
有关本发明的前述及其他技术内容、特点与功效，在以下配合参考图式的一较佳实施例的详细说明中，将可清楚的呈现。以下实施例中所提到的方向用语，例如：上、下、左、右、前或后等，仅是参考附加图式的方向。因此，使用的方向用语是用来说明并非用来限制本发明。此外，“A层(或组件)设置于B层(或组件)上”的用语，并不限定为A层直接贴覆接触B层表面的态样，例如A层与B层中间尚间隔其他积层亦为所述用语所涵盖范围。图式中，相同的组件是以相同的符号表示。图式中的各构成组件的比例，仅供清楚说明，实际大小并未依照图式中的比例绘制。
以下，通过较佳实施态样，具体地说明本发明，但本发明不限于这些实施态样，在不脱离本发明的要旨的范围内，可进行各种变形或变更。
图1是表示根据本发明的立体织物复合材料的制造方法的流程图。本发明的立体织物复合材料的制造方法，其是具有网孔的立体织物作为基材，制造所述基材表面具有涂层的立体织物复合材料的方法，包括以下步骤：提供一树脂组成物；将所述树脂组成物，通过一涂布机构，形成涂膜于所述基材的一侧或两侧的表面，得到一表面具有涂膜的基材的涂布步骤S1；以及将所述表面具有涂膜的基材，通过一开孔机构，破坏涂膜在网孔间的弯液面(meniscus)，得到表面开孔的立体织物复合材料的开孔步骤S2。本发明的立体织物复合材料的制造方法可还包含熟成步骤S3，在经过所述开孔步骤后，所得的立体织物复合材料放置于温度设定为所述树脂组成物具有流动性的温度的环境(例如玻璃转化温度Tg以上或熔点以上)，进行一特定期间的熟成处理。再者，本发明的制造方法可还包含基材前处理步骤SP。如图1所示，本发明的立体织物复合材料的制造方法的基材前处理步骤SP、涂布步骤S1、开孔步骤S2及熟成步骤S3，可具有各种组合，但不限于图1所示的例，例如作为变形例，各步骤可进行1次或2次以上。具体地，例如可进行涂布步骤2次，分别在基材表面形成涂膜。
图2是表示关于本发明的立体织物复合材料的剖面图，其中(a)表示2层外部层10a，10b及中间层20所构成的立体织物30，(b)表示涂层40覆盖于外部层10a,10b及中间层20的表面上所构成的立体织物复合材料1。图3中(a)表示图2中(a)所示的立体织物30的上视图及图3中(b)表示图2中(b)所示的立体织物复合材料1的上视图。
立体织物30，是2层外部层10a，10b及中间层20所构成，2层外部层10a，10b具有例如菱形的网孔，中间层为单丝(mono yarn)，结构像三明治般堆栈，也称为三明治立体网布，主要是由高分子合成纤维组成，可由精密经编机机台编织而成，2层外部层10a，10b间有密网支撑，使得表面的网状结构不会产生太大的变形，增强了布料的机械性质及色彩牢固度。立体网布能够广泛地应用于服饰、鞋材、床垫、帽材、透气鞋垫、运动防护材、医疗复合材等。立体织物30，亦可由市售品取得。
涂层40，可通过本发明的制造方法，形成于2层外部层10a，10b及中间层20的表面。树脂组成物可由选自聚酯、聚氨酯、聚酰胺、聚醇所成群的至少一种无规共聚物或嵌段共聚物所构成。需注意的是如图3所示，涂层40形成于立体织物30的表面后，仍存在有网孔15，具有立体网孔结构。此外，网孔15的缩小率，亦即(涂层形成前的网孔15的平均直径－形成后的网孔15的平均直径)/形成前的网孔15的平均直径的比值，较理想为80％以下，更理想为50％以下，更加理想为40％以下。具体地，本发明的立体织物复合材料，根据ASTM D737的透气率为100cfm(ft3/min)以上，较理想为300cfm以上，更理想为500cfm以上。
再者，于一实施例，所述无规共聚物或嵌段共聚物，可在所述相变化温度以下具有108Pa以上的杨氏模数。再者，根据ASTM D790的三点弯曲的抗弯折试验，使用跨距/长度/宽度/厚度约为16/40/4/1的测试片，测试速度15mm/min，变形量5％内无断裂点产生，所得的数值为抗弯折强度，本发明的立体织物复合材料的抗弯折强度可为120MPa以上，较理想为200MPa以上。所述无规共聚物或嵌段共聚物，较理想为聚酯共聚物。但本发明的立体织物复合材料的制造方法，不限于使用上述例示的树脂组成物。
于熟成步骤，其温度可设定为树脂组成物具有流动性的温度，例如所述树脂组成物的玻璃转化温度Tg或熔点Tm以上，例如(熔点10℃-50℃)以上。熟成处理的时间，随熟成温度而异，例如5分钟-24小时，考虑生产性，10分钟-8小时较理想。
于基材前处理步骤，在涂布步骤前，将基材通过一前处理机构，进行前处理，活化基材表面，提高基材与树脂组成物的黏着性。前处理机构，具体地例如包括可实施选自电浆处理、电晕处理、紫外线照射、臭氧处理、锚定处理、膨润处理及预热处理所成群的至少1种或2种以上的组合的机构。较理想为预热处理。
于一实施例，所述涂布机构包括淋膜装置、热压装置或热滚轮装置。
于一实施例，上述的方法中，所述开孔机构包括选自接触式开孔机构及非接触式开孔机构所成群的至少1种或2种以上的组合。于一实施例，上述的方法中，所述接触式开孔机构包括表面具有针状结构的平板或滚轮。于一实施例，上述的方法中，所述非接触式开孔机构包括低周波震荡器、高周波震荡器或烤箱。
于一实施例，上述的方法中，涂布步骤后，可还包括通过至少一组压入滚轮，使所述构成涂膜的材料渗入基材中的步骤。
再者，根据本发明的另一实施态样的涂布机，其是用于在具有网孔的基材上形成有孔涂膜的涂布装置，包括：将构成涂膜的材料成为流体的涂布装置，用以在基材表面形成涂膜；多个传动滚轮，连续传递长条状的基材；开孔装置，使通过所述开孔装置的基材形成连通基材的两表面的贯穿孔，使所述基材具有透气性。此处，所谓贯穿孔，不限于垂直于基材两表面的空孔，只要是连通基材的两表面，气体可流通的孔洞即可。
于一实施例，涂布机中，所述开孔装置包括选自接触式开孔装置及非接触式开孔装置所成群的至少1种或2种以上的组合。于一实施例，涂布机中，所述接触式开孔装置包括表面具有针状结构的平板或滚轮。于一实施例，涂布机中，所述非接触式开孔装置包括低周波震荡器、高周波震荡器或烤箱。
于一实施例，涂布机可还包括至少一组压入滚轮，位于所述构成涂膜的材料通过所述涂布装置形成涂膜于基材后，通过调整所述组压入滚轮间的距离或表面温度，使所述构成涂膜的材料渗入基材中。
于一实施例，涂布机中，所述涂布装置为一挤出机。
于一实施例，上述涂布机，可还包括冷却装置及/或切割机。
再者，于传送基材的路径中，依需要，上述涂布机可包括热滚轮或加热区域，亦可包括冷却区域。
再者，构成涂布机构或涂布机的各构成零件，依需要，可进行离型处理，离型处理例如含氟涂膜表面处理或聚硅氧(silicone)表面处理等，但不限于上述例。例如上述具有针状结构的平板或滚轮，进行离型处理较理想。再者，构成涂布机构的各构成零件，依需要，可进行表面镜面处理等。
上述制造步骤或使用涂布机时，涂膜可形成于基材的一表面或两表面，涂膜形成于基材的两表面时，可同时形成，亦可分别形成，涂膜的厚度会影响所得的立体复合材料的开孔率，依据所使用的立体织物的厚度、所期望的开孔率及复合材料所期望的硬度，可任意地调整。在通常的应用领域，涂膜的范围例如为0.02mm-0.5mm的范围，较理想为0.05mm-0.2mm的范围，或者较理想为立体织物的厚度的50％以下，更理想为立体织物的厚度的20％以下，更加理想为立体织物的厚度的10％以下。
再者，根据本发明的另一实施态样的立体织物复合材料，其是利用上述本发明的方法制造而得或使用上述本发明的涂布机制造而得。
图4是表示根据本发明的涂布机的一例的示意图，但是本发明的涂布机不限于包括图中的所有构成，可以依需要做任意的选择及组合。例如，涂布机可以不具备前处理装置。涂布机100包括前处理装置110，传送滚轮105a、105b、105c等，模头120a、120b，涂布滚轮125a、125b，压入滚轮140a、140b，热滚轮130(可用加热环境取代或不使用)，开孔装置150，冷却装置160及切割机170等。图5-图7是表示根据本发明的涂布机构或涂布装置的其他变形例的示意图，其中180a及180b表示压入及涂布滚轮。图8是表示根据本发明的开孔机构或开孔装置150的一例的示意图。上述图式仅用以具体说明本发明，但本发明的构成不限于上述图式所示的例。
综上所述，根据本发明的立体织物复合材料的制造方法及/或涂布机，可连续地制造具有透气性的立体织物复合材料外，降低生产成本，提高生产效率。根据本发明的立体织物复合材料的制造方法及/或涂布机所制造的立体织物复合材料，可具有质轻、透气性佳、追随性佳、操作性佳等的优点，依据复合材料的特性，可应用于例如服饰、鞋材、交通运输、建筑、农用及医疗等的各种领域。
以上虽以特定实施例说明本发明，但并不因此限定本发明的范围，只要不脱离本发明的要旨，熟悉本技艺者了解在不脱离本发明的意图及范围下可进行各种变形或变更。另外本发明的任一实施例或权利要求不须达成本发明所公开的全部目的或优点或特点。此外，摘要部分和标题仅是用来辅助专利文件搜寻之用，并非用来限制本发明的权利范围。

Claims (16)

1.一种立体织物复合材料的制造方法，其是具有网孔的立体织物作为基材，制造所述基材表面具有涂层的立体织物复合材料的方法，包括以下步骤：
提供一树脂组成物，所述树脂组成物为选自聚酯、聚氨酯、聚酰胺、聚醇所成群的至少一种无规共聚物或嵌段共聚物所构成；
将所述树脂组成物，通过一涂布机构，形成涂膜于所述基材的一侧或两侧的表面，得到一表面具有涂膜的基材的涂布步骤；以及
将所述表面具有涂膜的基材，通过一开孔机构，破坏涂膜在网孔间的弯液面，得到表面开孔的立体织物复合材料的开孔步骤；
其中所述表面开孔的立体织物复合材料所具有的网孔的缩小率为50％以下，且根据ASTM D737的透气率为100cfm以上，在相变化温度以下具有108Pa以上的杨氏模数。
2.如权利要求1所述的方法，还包括：一熟成步骤，在经过所述开孔步骤后，所得的立体织物复合材料放置于温度设定为所述树脂组成物具有流动性的温度的环境，进行一熟成处理。
3.如权利要求1或2所述的方法，还包括：一基材前处理步骤，在涂布步骤前，将基材通过一前处理机构，进行前处理，活化基材表面，提高基材与树脂组成物的黏着性。
4.如权利要求1或2所述的方法，其中所述涂布机构包括淋膜装置、热压装置或热滚轮装置。
5.如权利要求1或2所述的方法，其中所述开孔机构包括选自接触式开孔机构及非接触式开孔机构所成群的至少1种的组合。
6.如权利要求5所述的方法，其中所述接触式开孔机构包括表面具有针状结构的平板或滚轮。
7.如权利要求5所述的方法，其中所述非接触式开孔机构包括低周波震荡器、高周波震荡器或烤箱。
8.如权利要求3所述的方法，其中所述前处理机构包括可实施选自电浆处理、电晕处理、紫外线照射、臭氧处理、锚定处理、膨润处理及预热处理所成群的至少1种的组合的机构。
9.如权利要求1所述的方法，其中涂布步骤后，还包括通过至少一组压入滚轮，使所述树脂组成物渗入基材中的步骤。
10.一种涂布机，其是用于在具有网孔的基材上形成有孔涂膜的涂布装置，包括：
将构成涂膜的材料成为流体的涂布装置，用以在基材表面形成涂膜；
多个传动滚轮，连续传递长条状的基材；
开孔装置，使通过所述开孔装置的基材形成连通基材的两表面的贯穿孔，使所述基材具有透气性；
其中所述构成涂膜的材料为树脂组成物，所述树脂组成物为选自聚酯、聚氨酯、聚酰胺、聚醇所成群的至少一种无规共聚物或嵌段共聚物所构成，在相变化温度以下具有108Pa以上的杨氏模数；
所述具有网孔的基材为立体织物，表面形成有孔涂膜的基材所具有的网孔的缩小率为50％以下，且根据ASTM D737的透气率为100cfm以上。
11.如权利要求10所述的涂布机，其中所述开孔装置包括选自接触式开孔装置及非接触式开孔装置所成群的至少1种的组合。
12.如权利要求11所述的涂布机，其中所述接触式开孔装置包括表面具有针状结构的平板或滚轮。
13.如权利要求11所述的涂布机，其中所述非接触式开孔装置包括低周波震荡器、高周波震荡器或烤箱。
14.如权利要求10所述的涂布机，还包括至少一组压入滚轮，位于所述构成涂膜的材料通过所述涂布装置形成涂膜于基材后，通过调整所述组压入滚轮间的距离或表面温度，使所述构成涂膜的材料渗入基材中。
15.如权利要求10所述的涂布机，其中所述涂布装置为一挤出机。
16.一种立体织物复合材料，其是利用如权利要求1至9任一项所述的方法制造而得或使用如权利要求10至15任一项所述的涂布机制造而得。
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