CN112585199B - 能够热粘合的防水透湿膜和其制造方法 - Google Patents

能够热粘合的防水透湿膜和其制造方法 Download PDF

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CN112585199B
CN112585199B CN201980053952.0A CN201980053952A CN112585199B CN 112585199 B CN112585199 B CN 112585199B CN 201980053952 A CN201980053952 A CN 201980053952A CN 112585199 B CN112585199 B CN 112585199B
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waterproof moisture
film
permeable
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CN112585199A (zh
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张根勋
车真燮
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Blitz Textile Co ltd
Silang International Ltd
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Abstract

本发明涉及一种通过使用其中点涂在表面上的热熔粘合剂能够热粘合到布料的防水透湿膜100及其制造方法。特别地，本发明涉及一种通过应用于户外衣服的制造而具有优异的防水透湿性且能够简化所述户外衣服的制造工艺的能够热粘合的防水透湿膜100及其制造方法。

Description

能够热粘合的防水透湿膜和其制造方法
技术领域
本发明涉及一种用于制造户外用途的功能性布料的防水透湿膜和其制造方法，其中通过对防水透湿膜施加热和压力来附接到诸如织物等的布料基材的一侧面上可以容易地制造用于户外衣服的功能性布料，并且可以涉及一种具有优异的防水透湿功能的能够热粘合的防水透湿膜和其制造方法。
背景技术
通常，防水透湿布料是指一种布料材料，其通过使衣服内部的汗水等的水蒸气通过到外部排出并且防止外部的雨水等的水分渗入衣服内，从而在雨和雪中防水(waterproof)并且通过排出汗水(breathable)帮助控制穿着者的体温并保持舒适感。
这种防水透湿布料具有致密的结构和可弯曲的气孔，因此也具有防风(windproof)功能，即使在寒冷的环境中由于活动量增加而出汗时，这种防水透湿布料应用为人体与环境之间的媒介，通过调节热和水分等的传递，使汗水不会凝结或降低体温。
近年来，随着人们对健康和休闲活动的兴趣日益增加，防水透湿布料已应用于各个领域，并且随着高档化和康乐的繁荣兴起，这种功能正在进一步被强调。另外，这些防水透湿布料的使用范围逐渐扩大到户外衣服、登山服、野外外出衣服和睡袋等。
同时，随着引入每周52小时的工作制，休闲时间增加，并且重视舒适和消闲生活的生活方式成为一种趋势，户外衣服每年都有很高的销售增长率。
用于制造如上所述的防水透湿布料的技术包括湿法、干法和层压法等，所述层压法是通过在单独制造具有防水透湿性的膜(membrane)后使用粘合剂将其与布料结合来制造防水透湿布料的方法。
细看有关通过这种层压法制造用于制造防水透湿布料的膜的现有技术时，在韩国公开申请公布第10-2017-0127760号(2017.11.22)中揭示了一种单方向防水透湿布料的多层膜及其制造方法，其中所述多层膜包括：第一多孔层，其包括由疏水性聚合物形成的第一纳米纤维；无孔层；以及第二多孔层，其含有吸水性物质或包括涂覆有吸水性物质的第二纳米纤维，并且在韩国公开申请公布第10-2010-0126940号(2010.12.03)中揭示了一种通过在交联(cross link)状态下将细微聚氨酯珠(beads)层压在离型纸表面上并在聚氨酯珠粒之间形成许多细微气孔而具有优异的透气性和透湿性的防水透湿膜及其制造方法。另外，在韩国公开申请公布第10-2017-0068984号(2017.06.20)中揭示了一种包括织物基材；在所述织物基材的粘合表面上形成的表面改性层；转印到所述表面改性层的点状粘合剂构件；以及通过所述点状粘合剂构件粘合到所述织物基材的膜的防水透湿布料及其制造方法。
然而，根据这种现有技术的用于制造防水透湿布料的膜具有以下问题：在所述膜粘合到布料时存在液态粘合剂的不均匀涂覆分布，导致透湿效率不均匀，并且液态粘合剂渗透到布料上导致透湿性降低。另外，粘合到布料基材的膜的剥离耐久性或耐磨损性差，并且所述防水透湿膜的表面在接触汗水等的水分时发生体积膨胀的膨润现象即溶胀(swelling)现象，因此存在衣服的外观变差的问题。
发明内容
技术问题
本发明涉及一种通过使用其中点涂在表面上的热熔粘合剂能够热粘合到布料基材15的防水透湿膜100及其制造方法。特别地，本发明涉及一种通过应用于户外衣服的制造而具有优异的防水透湿性且能够简化所述户外衣服的制造工艺的能够热粘合的防水透湿膜100及其制造方法。然而，本发明要解决的问题不限于上述问题，并且本领域技术人员将从以下描述中清楚地理解未提及的其他问题。
技术方案
用于解决上述问题的本发明的能够热粘合的防水透湿膜100的特征在于包括：膜层50；设置于所述膜层50的下部的脱模层70；以点状转印到所述膜层50的上部的基层25；以及在所述基层25的上部形成的热熔粘合剂层30。此外，所述能够热粘合的防水透湿膜100的透湿度为1000g/m2/24h至50000g/m2/24h，并且优选地在所述膜层50上设置有保护层10。
所述热熔粘合剂层30由聚酰胺树脂、聚氨酯树脂、乙烯-醋酸乙烯酯共聚物(ethylene-vinyl acetate copolymer：EVA)树脂和聚酯树脂中的任何一个组成，所述基层25由丙烯酸树脂、聚氨酯树脂、聚酰胺树脂、聚酯树脂、聚烯烃树脂、聚氯乙烯(polyvinylchloride：PVC)树脂和EVA树脂中的任何一个组成，并且所述膜层50优选由聚氨酯、聚酯、聚酰胺和聚四氟乙烯中的任何一个组成。
并且，在以点状转印到所述膜层50的上部的基层25中，所述点形成为1个/cm2至220个/cm2，并且所述膜层50的厚度优选为0.15mm至0.30mm。
此外，所述用于制造防水透湿布料的能够热粘合的防水透湿膜100可以通过与布料基材15热粘合来制造防水透湿布料。
本发明的制造能够热粘合的防水透湿膜100的方法包括：准备在下部形成有脱模层70的膜层50的第一步骤；将基层25以点状转印到所述膜层50的上部的第二步骤；将热熔粘合剂粉末35散布在所述基层25的上部的第三步骤；抽吸和除去除了安置于所述基层25的上部的热熔粘合剂粉末35以外的热熔粘合剂粉末35的第四步骤；通过热固着安置于所述基层25的上部的热熔粘合剂粉末35来形成热熔粘合剂层30的第五步骤；以及冷却所述基层25和热熔粘合剂层30的第六步骤，特别地，优选地包括在所述膜层50上添加保护层10的步骤。
有益效果
通过使用平板压机或辊压机等来将根据本发明的能够热粘合的防水透湿膜100热粘合到用于制造衣服的布料基材15上，从而容易制造具有防水透湿性的功能性布料。此外，在缝制工艺中，可以通过层压工艺制造具有防水透湿性的功能性布料，因此减少用于户外的衣服的制造步骤，从而增强最终产品的价格竞争力。并且，本发明的能够热粘合的防水透湿膜100由于不使用溶剂，因此与现有的在布料上涂覆粘合剂后将膜与布料粘合的方法相比，具有环保性，并且还提高了户外衣服的设计完整性的效果。
附图说明
图1为根据本发明的第一实施例的能够热粘合的防水透湿膜100的截面图，
图2为根据本发明的第二实施例的能够热粘合的防水透湿膜100的截面图，
图3为应用了根据本发明的第二实施例的能够热粘合的防水透湿膜100的防水透湿布料的示意性截面图，
图4为本发明的能够热粘合的防水透湿膜100的俯视图，
图5为本发明的能够热粘合的防水透湿膜100的制造工艺图，以及
图6为根据本发明的一实施例的在基础树脂涂覆工艺中使用的上部筛辊100的示意图。
具体实施方式
在本申请中，诸如“包括”或“具有”等的术语旨在表示存在说明书中所描述的特征、数字、步骤、组件、部件或其组合，不预先排除存在或添加一个或以上的其他特征、数字、步骤、操作、组件、部件或其组合。
另外，除非另外定义，否则本文中使用的所有术语(包括技术或科学术语)具有与本发明所属领域的普通技术人员通常所理解的相同含义。诸如在常用字典中定义的那些术语应被解释为具有与相关技术背景下的含义一致的含义，除非在本申请中明确定义，否则不应以理想的或过于正式的意义来解释。
在下文中，将参考附图详细描述根据本发明的能够热粘合的防水透湿膜100和其制造方法。在本发明中附有的图1为根据本发明的第一实施例的能够热粘合的防水透湿膜100的截面图，图2为根据本发明的第二实施例的能够热粘合的防水透湿膜100的截面图，图3为应用了根据本发明的第二实施例的能够热粘合的防水透湿膜100的防水透湿布料的示意性截面图，图4为本发明的能够热粘合的防水透湿膜100的俯视图，图5为本发明的能够热粘合的防水透湿膜100的制造工艺图，以及图6为根据本发明的一实施例的在基础树脂涂覆工艺中使用的上部筛辊100的示意图。
本发明的能够热粘合的防水透湿膜100通过在制造户外衣服等时粘合于布料基材15，从而赋予所述布料基材15防水透湿性。如图1所示，本发明的能够热粘合的防水透湿膜100的特征在于包括：膜层50；设置于所述膜层50的下部的脱模层70；以点状转印到所述膜层50的上部的基层25；以及在所述基层25的上部形成的热熔粘合剂层30。在以点状(dot)形成的基层25的上部上，所述热熔粘合剂层30以点状形成，从而形成双点层60。
换言之，根据本发明的第一实施例，为了制造本发明的能够热粘合的防水透湿膜100，首先需要形成基底层的膜层50。所述膜层50是为了制造户外衣服而粘合到布料基材15以赋予布料基材15防水透湿性的组件。
换言之，所述膜层50是具有由细微气孔构成的微孔结构(microporous)的薄膜，其可以通过使用聚四氟乙烯(polytetrafluoroethylene)、聚氨酯(polyurethane)、聚酯(polyester)和聚酰胺(polyamide)等来制造。
换言之，聚四氟乙烯能够在膜上均匀地形成气孔来表现出优异的透湿性，聚氨酯易于控制在膜中形成的气孔的尺寸，并且聚酯具有优异的透湿性和防水性，同时具有优异的触感和耐久性以及出色的外观。另外，聚酰胺具有优异的耐腐蚀性、耐磨损性、耐化学性和绝缘性，因此被广泛用作防水透湿膜。
并且，在本发明中使用的膜层50的厚度优选为0.15mm至0.30mm。在具有上述厚度的情况下，当应用于衣服时，可以制造出具有优异的透气性和防水性的衣服，并且可以制造出防水透湿性以及防风和轻量性等优异的户外衣服。另外，由于其不降低户外衣服的柔软性而使活动性方便，因此可以制造各种功能性衣服产品。
并且，本发明的能够热粘合的防水透湿膜100在所述膜层50的下部具有脱模层70。
通常，脱模层70由具有所谓不能很好地粘合于压敏胶粘剂成分或粘合成分的防粘性的膜形成，并通过附接于所述膜层50来保护所述膜层50，且用于防止膜层50受由灰尘或异物等引起的污染。另外，当完成衣服的制造时，可以使用其易于剥离的特性来容易地将其去除。
另外，本发明的能够热粘合的防水透湿膜100包括以点状转印到所述膜层50的上部的基层25。在制造本发明的能够热粘合的防水透湿膜100的工艺中，优选设置基层25，以防止膜层50粘合到其他布料，并防止由于重力而下垂，从而改善工艺性并防止可加工性下降的问题。
所述基层25可以通过使用丙烯酸树脂、聚氨酯树脂、聚酰胺树脂、聚酯树脂、聚氯乙烯树脂和EVA树脂中的任何一个来形成。在本发明中，如图1和图2所示，优选将所述基层25以点状转印到所述膜层50的上部。
并且，热熔粘合剂层30形成在所述基层25的上部。所述热熔粘合剂层30是用于将膜层50粘合到用于制造衣服的布料基材15的组成，在制造本发明的能够热粘合的防水透湿膜100后，通过对其施加热来对所述热熔粘合剂层30进行熔融和加压，从而将所述能够热粘合的防水透湿性膜100热粘合到布料基材15。
所述热熔粘合剂是指通过不使用水或溶剂，而是使用在室温下呈固态的不挥发，不易燃的热塑性树脂(thermoplastic-resin)并对其施加热使其熔融而以液态形式涂覆在被粘物上之后，在冷却和固化时表现出粘合力的热熔粘合剂。
在本发明中，如图1和图2所示，所述基层25和设置于所述基层25的上部的热熔粘合剂层30形成双点层60。
可以适当地选择和实现形成在本发明的膜层50上的双点层60的密度。
换言之，图4是其中形成有双点层60的本发明的能够热粘合的防水透湿膜100的俯视图，如图4所示，所述双点层60的形成密度可以表示为在所述能够热粘合的防水透湿膜100的表面的1cm2的内部中形成的双点层60的数量，即单位密度。换言之，在本发明中，双点层60的单位密度优选为1个/cm2至220个/cm2。
另外，如图4所示，所述双点层60的形成密度可以表示为在1英寸(inch)长的线上一列形成的双点层60的数量，即线型密度。在本发明中，所述双点层60的线型密度优选为7个至40个。
当在如上所述的单位密度和线型密度的范围内形成双点层60时，本发明的能够热粘合的防水透湿膜100的透湿度可以维持为1000g/m2/24h至5000g/m2/24h，因此透湿度不会降低而具有优异的透湿度。并且，由于所述热熔粘合剂层30形成为具有最优异的粘合力，因此膜层50可以具有优异的剥离耐久性和耐磨损性。
另外，根据本发明的第二实施例，可以在膜层50上添加保护层10。换言之，如图2所示，根据本发明的第二实施例的能够热粘合的防水透湿膜100具有保护层10，其设置于所述膜层50的下部并保护所述膜层50。如图2和图3所示，所述保护层10通过附接于膜层50来保护所述膜层50，从而保护在所述膜层50中形成的细微气孔，并且层压所述保护层10以增强膜层50的表面强度。所述保护层10由聚氨酯膜形成，并且优选为由厚度为1μm至2μm的聚氨酯膜层压。
然后，将如上所述形成的本发明的能够热粘合的防水透湿膜100热粘合到布料基材15，从而使得可以制造用于制造户外衣服的防水透湿布料。
在下文中，将参照图5描述根据本发明的能够热粘合的防水透湿膜100的制造方法。
图5为示出根据本发明的能够热粘合的防水透湿膜100的制造工艺的工艺图。在根据本发明的能够热粘合的防水透湿膜100的制造工艺中，第一步骤为准备在下部形成有脱模层70的膜层50。如图5所示，如上所述的在下部形成有脱模层70的膜层50被投入至上部筛辊100和下部辊200之间并沿箭头方向移送。
并且，在第二步骤中，在所述膜层50的上部形成基层25。在所述第二步骤中，首先，使用旋转的上部筛辊100将基础树脂熔融并以点状转印，从而在膜层50的上部形成基层25。
换言之，在所述第二步骤中，在上部筛辊100将基础树脂熔融后，通过设置在所述上部筛辊100的一侧的刮片150将基础树脂的熔融物以点状转印到所述膜层50上以形成基层25。
所述第二步骤优选地使用上部筛辊100进行。特别地，在通过使用上部筛辊100将基础树脂转印成点状时所制得的膜层50具有优异的触感和悬垂性(drapability)。
另外，如图6所示，所述上部筛辊100的熔融所述基础树脂并流出的流出孔15优选为每cm230个至180个，并且所述流出孔15的直径优选为350μm至750μm。
当更详细地描述形成所述基层25的步骤时，如图5所示，通过上部筛辊100将所述将基础树脂以点状涂覆在所述膜层50的上部，从而形成基层25。此时，以点状转印到所述膜层50的上部的基础树脂的量优选为10g/㎡至30g/㎡，当要涂覆的基础树脂的量超过30g/㎡时，布料的质地过度硬化并且触感降低，并且当要涂覆的基础树脂的量不足10g/㎡时，由于结合强度不足，因此不能获得足够的耐久性来承受涤，并且结果所述膜层50和布料基材15之间的粘合力可变得不良。
所述基层25的转印速度最优选为每分钟20米至30米。并且，根据本发明的一实施例，所述基础树脂的熔融粘度最优选为7000cps至45000cps。
所述基层25是通过对丙烯酸树脂、聚氨酯、聚酰胺、聚酯、聚氯乙烯(PVC)和乙烯-醋酸乙烯酯共聚物(ethylene-vinyl acetate copolymer：EVA)树脂中的任何一个基础树脂施加适当的温度来使其熔融来形成的。
之后，作为第三步骤，将热熔粘合剂粉末35散布在所述基层25的上部。
在第二步骤中形成为点状的基层25是通过对基础树脂施加合适的温度而熔融的熔融物，并且通过所述上部筛辊100以点状转印到膜层50的上部。在所述第三步骤中，在以点状转印的基础熔融物冷却并固化之前，将所述热熔粘合剂粉末35散布在基层25的上部。
换言之，填充在漏斗160中的具有粒子尺寸为80μm至200μm的热熔粘合剂粉末35由散射辊250供应至形成有所述基层25的膜层50，并且此时，振动刷子251将热熔粘合剂粉末35散布到所述基层25的上部。
此时，所述热熔粘合剂粉末35以粉状散布到膜层50的上部，并且安置于尚未固化的基层25的上部，从而形成点状的热熔粘合剂层30。
此后，执行第四步骤，其中通过抽吸装置300抽吸并除去除了安置于所述基层25的上部的热熔粘合剂粉末35以外的散布到膜层50等的热熔粘合剂粉末35。
由于形成所述基层25的基础树脂处于在以点状转印到膜层50的上部后并在固化之前的状态，安置于所述基层25的热熔粘合剂粉末35可以附接到所述基层25的上部。然而，在第四步骤中，未能安置于所述基层25并掉落在所述膜层50上的热熔粘合剂粉末35由所述抽吸装置300抽吸以从所述膜层50的表面上除去。
接下来，执行第五步骤，其中除去了未能安置于基层25的热熔粘合剂粉末35的膜层50通过拉幅机350来蒸发形成在所述膜层50的上部的双点层60中所含有的水分，并且将所述基层25和形成在所述基层25的上部的热熔粘合剂层30热固着。
此时，所述拉幅机350的温度条件可以根据所述热熔粘合剂的熔融温度而适当设定并实施。
在所述第五步骤中，安置于所述基层25的上部的热熔粘合剂粉末35在被熔融的同时在所述基层25的上部形成点状的热熔粘合剂层30。
此时，所述热熔粘合剂层30形成为15g/m2至20g/m2使得在之后热粘合到布料基材15后形成最佳粘合力，从而可以优异地形成膜层50的剥离耐久性和耐磨损性。
如上所述，在将基层25以点状转印到膜层50的上部后，通过在所述基层25的上部以点状形成热熔粘合剂层30来完成双点层60的形成。
并且，在完成所述第五步骤之后，执行第六步骤，其中冷却由所述基层25和热熔粘合剂层30组成的双点层60。在所述第六步骤中，通过使用冷却辊400来冷却所述双点层60，使得能够以后进行卷绕。
另外，根据本发明的第二实施例，可以添加在所述脱模层70的上部添加保护层10的步骤。
如上所述，所述保护层10通过层压到所述脱模层70的一表面以保护膜层50和增强表面强度。所述保护层10由聚氨酯膜组成，并且所述聚氨酯膜厚度优选为1μm至2μm。由如上所述的聚氨酯膜组成的保护层10可以通过使用凹印辊(gravure roll)等在所述脱模层70和膜层50之间层压而形成。
对通过如上所述的步骤而完成制造的本发明的能够热粘合的防水透湿膜100施加热和压力来将其热粘合到用于制造衣服的布料基材，从而使得可以制造具有防水透湿性的功能性布料。此外，在缝制过程中，可以通过层压工艺制造具有防水透湿性的功能性布料，因此减少用于户外的衣服的制造步骤，从而增强最终产品的价格竞争力。并且，本发明的能够热粘合的防水透湿膜100是环保的，并且具有提高户外衣服的设计完整性的效果。
已经参考附图中所示的试验例描述了本发明，但是这些仅仅是示例性的，并且本领域普通技术人员将理解，由此可以进行各种修改和等同的其他试验例。另外，与本发明有关的本领域普通技术人员将能够理解，在不改变本发明的技术精神或基本特征的情况下，可以容易地转换成其他具体形式。因此，应当理解，上述实施例在所有方面都是示例性的而非限制性的，并且本发明的真正技术保护范围应该由所附权利要求的技术精神来确定。

Claims (10)

1.一种用于制造防水透湿布料的能够热粘合的防水透湿膜(100)，其附接于布料基材(15)并包括：
膜层(50)，其中所述膜层(50)的厚度在0.15mm至0.30mm的范围中；
设置于所述膜层(50)的下部的脱模层(70)；
以点状转印到所述膜层(50)的上部的基层(25)；以及
在所述基层(25)的上部以点状形成的热熔粘合剂层(30)，
其中，所述基层(25)和所述热熔粘合剂层(30)形成双点层(60)。
2.根据权利要求1所述的用于制造防水透湿布料的能够热粘合的防水透湿膜(100)，其中，
所述能够热粘合的防水透湿膜(100)的透湿度为1000g/m2/24h至50000g/m2/24h。
3.根据权利要求1所述的用于制造防水透湿布料的能够热粘合的防水透湿膜(100)，其中，
在所述膜层(50)上设置有保护层(10)。
4.根据权利要求1所述的用于制造防水透湿布料的能够热粘合的防水透湿膜(100)，其中，
所述热熔粘合剂层(30)由选自聚酰胺树脂、聚氨酯树脂、乙烯-醋酸乙烯酯共聚物(EVA)树脂和聚酯树脂中的一个组成。
5.根据权利要求1所述的用于制造防水透湿布料的能够热粘合的防水透湿膜(100)，其中，
所述基层(25)由选自丙烯酸树脂、聚氨酯树脂、聚酰胺树脂、聚酯树脂、聚烯烃树脂、聚氯乙烯(PVC)树脂和乙烯-醋酸乙烯酯共聚物(EVA)树脂中的一个组成。
6.根据权利要求1所述的用于制造防水透湿布料的能够热粘合的防水透湿膜(100)，其中，
所述膜层(50)由选自聚氨酯、聚酯、聚酰胺和聚四氟乙烯中的一个组成。
7.根据权利要求1所述的用于制造防水透湿布料的能够热粘合的防水透湿膜(100)，其中，
所述基层(25)以1个/cm2至220个/cm2的密度以点状转印到所述膜层(50)的上部。
8.一种防水透湿布料，包括：
布料基材(15)；以及
所述权利要求1至7中任一项的能够热粘合的防水透湿膜(100)，其热粘合于所述布料基材(15)的一侧。
9.一种制造用于制造防水透湿布料的能够热粘合的防水透湿膜(100)的方法，包括:
准备在下部形成有脱模层(70)的膜层(50)的第一步骤；
将基层(25)以点状转印到所述膜层(50)的上部的第二步骤；
将热熔粘合剂粉末(35)散布在所述基层(25)的上部的第三步骤；
抽吸和除去除了安置于所述基层(25)的上部的热熔粘合剂粉末(35)以外的热熔粘合剂粉末(35)的第四步骤；
通过热固着安置于所述基层(25)的上部的热熔粘合剂粉末(35)来形成点状的热熔粘合剂层(30)的第五步骤；以及
冷却所述基层(25)和热熔粘合剂层(30)的第六步骤。
10.根据权利要求9所述的制造用于制造防水透湿布料的能够热粘合的防水透湿膜(100)的方法，其进一步包括：
在所述膜层(50)上添加保护层(10)的步骤。
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