CN1214089A - 非织造纤维垫及其成形方法 - Google Patents

非织造纤维垫及其成形方法 Download PDF

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Publication number
CN1214089A
CN1214089A CN97193188A CN97193188A CN1214089A CN 1214089 A CN1214089 A CN 1214089A CN 97193188 A CN97193188 A CN 97193188A CN 97193188 A CN97193188 A CN 97193188A CN 1214089 A CN1214089 A CN 1214089A
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China
Prior art keywords
fiber
adhesive
fibre
fortifying fibre
fiber mat
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CN97193188A
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CN1061112C (zh
Inventor
G·S·荷尔威格
S·W·米勒
K·A·霍斯好德
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Owens Corning
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Owens Corning Fiberglas Corp
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2008—Fabric composed of a fiber or strand which is of specific structural definition

Abstract

本发明是一种适合用来增强弹性铺地织物片材(如乙烯基铺地织物)的非织造纤维垫。该非织造纤维垫是至少包含半卷曲纤维(18)和稍弯曲纤维(20)的增强纤维(14)的片材。最好,大部分(如果不是全部)增强纤维(14)是玻璃制的。然而,包括玻璃纤维和合成纤维的增强纤维(14)也是符合要求的。甚至只包含非玻璃纤维的增强纤维(14)也是可能的。至少采用一种聚合物粘合剂将增强纤维(14)粘结在一起,以便使纤维垫成为一种可用作增强弹性铺地织物片材的基材,如用作乙烯基铺地织物的中间层。由于采用包含不完全直的并能互相联锁的增强纤维(14)的非织造纤维垫,一种衬有这种纤维垫的弹性铺地织物片材就能显示出良好的平面压缩性。

Description

非织造纤维垫及其成形方法
相关申请介绍
本申请书是下列两件美国专利申请的部分继续。其中第一件于1994年9月21日提出申请、申请号为08/310183，标题为不规则状双组分玻璃纤维的加工方法及其制品。第二件于1996年2月29日提出申请、申请号为08/609071，标题为浸渍纤维状材料的成形方法。这两篇专利已转让给本申请的受让人。
技术领域
本发明涉及用来增强弹性铺地织物片材的纤维垫，尤其涉及可允许弹性铺地织物片材有一定程度的平面压缩位移的非织造纤维垫，更具体地说，涉及一种用作乙烯基铺地织物增强中间层的可压缩纤维垫。
背景技术
弹性铺地织物片材，如乙烯基铺地织物已广泛地用于住宅建筑中。一种如在欧洲使用的乙烯基铺地织物通常是由包括一层防磨层、一层印花/泡沫层、一层玻璃纤维垫及一层底层的若干层所构成的。防磨层通常是聚氨酯，它提供具有良好耐久性所必需的硬的耐磨表面。印花/泡沫层载有装饰性印花，并且是经化学发泡和压有花纹的。玻璃纤维层通常是以适当的粘合材料制的35克/米2-60克/米2的玻璃纤维垫。底层通常是与印花/泡沫层相同的乙烯基薄膜，该底层可以是实心的或是泡沫状的，并且完全包裹了玻璃纤维垫。
与用毛毡或纸作载体制造的铺地材料不同，玻璃纤维垫是一种具有适应铺地材料制造时经受涂布和印花处理的尺寸稳定的基材。以毛毡作底层的乙烯基铺地织物常常是粘合在地板表面上的。作为中间层的增强玻璃纤维垫的作用是产生一种抗卷曲的铺地织物，使铺地织物适宜于以活动式铺设。此外，这种夹层结构是非常柔软的，使用户可以容易地自行铺设。
包含这种玻璃纤维垫中间层的乙烯基铺地织物已在欧洲广泛使用。然而，由于房屋结构技术上的差别，在乙烯基铺地织物中使用作为增强层的全玻璃纤维垫的情况没有为美国普遍所接受，因为在欧洲流行采用混凝土地面，而在美国则较广泛采用木质地面体系。这种经玻璃纤维增强的乙烯基铺地织物铺设在混凝土地面上时，需要有较高的尺寸稳定性，但铺设在木质地面上时，可能会引起一些问题。木质地面会随温度和湿度的变化而发生较大的尺寸改变。在冬季，木质地面往往完全变干，木材收缩可高达0.5％。除非铺地织物会随下层地面的尺寸变化而能压缩(即收缩)，否则铺地织物可能出现弯折。
先前用来增强乙烯基铺地织物的玻璃纤维垫通常是刚性的并具有高的抗平面压缩位移性能。一种用作乙烯基铺地织物中间层的常规增强垫是用直径为9-11微米，长为6毫米的纺织用玻璃纤维制成的。这类纤维通常是采用刚性聚合物粘合剂(如脲醛树脂或聚乙烯醇)粘结在一起的。这类玻璃纤维增强垫的高压缩硬挺度在制造铺地织物过程中基本上是不会改变的。
美国专利4849281公开了一种潜在的解决因采用这种玻璃纤维增强层所引起的高压缩硬挺度问题的方法。该方法公开的玻璃纤维垫是由大部分玻璃棉纤维和少量纺织用玻璃纤维的混合物制成。这些玻璃纤维是在乙烯基涂层中经添加增塑剂后软化的、交联的苯乙烯-丁二烯弹性体粘合剂粘结的。大部分短的、松散的玻璃棉纤维和橡胶状粘合剂的混合物能允许相应的铺地织物有一定量的压缩位移。这种压缩性本身又可降低铺设在木质地面上的铺地织物发生弯折的可能性。
虽然美国专利4849281中公开的玻璃纤维垫提供了一种可能解决高压缩硬挺度问题的方法，但仍然需要提供使弹性铺地织物片材具有更好的平面压缩性的、工业上可行的纤维垫。
本发明公开内容
根据本发明原理，提供一种适用作增强弹性铺地织物片材(如乙烯基铺地织物)的非织造纤维垫可以满足这种需要。根据本发明原理，也提供了一种制造这种纤维垫的方法。在纤维垫制造的一个阶段，本发明纤维垫可以是一种湿法成网非织造纤维基网中或纤维基垫。这种基垫可包含多种组合成片材的增强纤维。最好，大多数(如果不是全部的话)增强纤维是由玻璃制造的。然而，包括玻璃纤维和合成纤维的增强纤维也是可符合要求的。本文所用名词玻璃是指包括任何玻璃质无机物质，如岩石、矿渣和玄武石以及传统意义上的玻璃。本文所用名词合成纤维是指包括任何具有合适增强特征的、由适用聚合物(如聚酯、聚烯烃、尼龙、芳酰胺、聚苯硫醚)制造的，以及由适用的非玻璃陶瓷物质(如碳化硅SiC)、氮化硼制造的纤维的人造纤维。
可采用一种多种粘合剂将增强纤维粘结在一起形成片材，以便至少使该基垫能继续在线加工或卷绕成卷筒以供后续离线加工成本发明非织造纤维垫。可用于基垫的粘合剂包括热塑性聚合物粘合剂。这些粘合剂可以呈颗粒状(如聚(乙烯醇)粉末)、纤维状(如由氯乙烯共聚物或共聚聚酯制的)，或者是两者混合物。这些粘合剂至少部分是以热熔方式使增强纤维粘结的。
本发明是以下述发明为基础的(至少是部分)，这项发现就是：通过采用包含不完全直的、并能相互联锁的增强纤维的非织造纤维垫，可获得具有改进的平面压缩性的弹性铺地织物片材。过去只采用比较直的纤维。采用包括卷曲纤维和半卷曲纤维或半圈纤维的增强纤维已经获得了满意的结果。据信，通过采用至少半卷曲纤维作为全部或绝大部分增强纤维至少可使以前的纤维垫有某些改善。卷曲的或其它半卷曲(即有弯曲部分)的增强纤维看来象是起着小弹簧堆的作用。至少当这种纤维垫衬入弹性铺地织物片材中时，含这些弹簧状纤维的纤维垫能阻止其平面伸展，并仍允许其平面压缩位移的程度高于以前的纤维垫。
在纤维垫制造的最后阶段，本发明非织造纤维垫可以是包括至少半卷曲纤维的增强纤维片材。至少采用一种聚合物粘合剂将增强纤维粘结在一起，以便使纤维垫成为一种可用作增强弹性铺地织物片材的基材，如用作乙烯基铺地织物的中间层。对于纤维垫来说，拥有包含卷曲状纤维，而每一卷曲状纤维有至少一个卷曲圈的卷曲的增强纤维是理想的。半卷曲状纤维和卷曲状纤维是随机地或不规则地配置在整个片材上也是理想的。
将不规则状玻璃纤维(如那些公开在美国专利5431992中的纤维)短切或用其它方法切成较短的、长度不等的纤维以制得卷曲状纤维、半卷曲状纤维以及甚至较直的或稍弯曲的纤维，通过采用由这种纤维形成的增强纤维已得到了满意的结果。据信，由具有适用增强特性的非玻璃物质制的不规则或随机形状的纤维也可用来制造合格的增强纤维。适用的非玻璃物质包括合成材料如高温工程热塑性聚合物和热固性聚合物以及非玻璃陶瓷材料。也可认为，这些非玻璃的呈不规则状的纤维可用来代替不规则状的玻璃纤维或可加到不规则状的玻璃纤维中。可用来补充由这类不规则状纤维形成的增强纤维的其它纤维包括较直的合成纤维、纺织用玻璃纤维以及玻璃棉纤维。
聚合物粘合剂可包括一种初次粘合剂，这种粘合剂的作用是至少将增强纤维粘结在一起，以使得到的片材能接着加工成纤维垫。聚合物粘合剂也可包括一种二次粘合剂，这种粘合剂的作用是将增强纤维粘结在一起，以使该制得的纤维垫具有显著的抗平面伸长性而仍允许可有明显的平面压缩位移。另一方面，聚合物粘合剂可以是适于将增强纤维粘结在一起的单一粘合剂。
本发明的另一个方面，提供一种用于制造根据本发明的上述纤维垫的方法。就一种方法来说，多种不规则状纤维中的每根纤维都被短切或用其它方法切成长度不等的(如约0.5英寸(12.7毫米)-约2.0英寸(50.8毫米))随机形状的纤维。其中某些随机形状纤维是卷曲成一个或多个圈的，而其它纤维只是呈半圈卷曲或是较直的(即稍弯曲的)。提供的增强纤维是以包含至少是随机形态纤维的淤浆状态。该淤浆可经脱水或其它方法成形为湿法成网非织造增强纤维基垫。在加工过程的某个阶段，将至少一种热固性或热塑性粘合剂涂布到增强纤维上。湿法成网基垫经干燥，并通过使热固性粘合剂交联和/或使热塑性粘合剂固化的方法(无论哪个方法是适用的)使粘合剂固化而形成非织造纤维垫。干燥和固化步骤可同时进行也可分别进行。
作为一种制得不规则状纤维的方法，该方法也可包括由具有不同热膨胀系数的、至少两种不同的玻璃纤维形成多种不规则状纤维的步骤，如根据美国专利5431992所介绍的方法。除了由至少两种不同的玻璃纤维形成多种不规则状纤维的步骤外，该方法还可包括将每种不同类型增强纤维短切或以其它方法切断成多种长度的短纤维、这些其它类型增强纤维可包括合成纤维、纺织用玻璃纤维及玻璃棉纤维。将这些增强纤维以任何方式组合混合成为淤浆的一部分是理想的。
本发明方法的一个实施方案中，将粘合剂涂布到增强纤维上的步骤可包括向淤浆供入至少一种热塑性初次粘合剂，该热塑性粘合剂在淤浆中呈微粒状、纤维状或两者兼有的形态。可对该热塑性粘合剂进行加热，例如在干燥湿法成网纤维垫步骤时进行加热以使至少部分热塑性粘合剂热熔入增强纤维中。如果需要，或在湿法成网纤维垫初步干燥前或在其初步干燥后，可将二次热塑性和/或热固性粘合剂涂布在增强纤维上。干燥湿法成网纤维垫的步骤可包括至少在涂布二次粘合剂后的纤维垫的干燥操作。干燥湿法成网纤维垫的步骤也可包括二次粘合剂涂布后等待纤维垫干燥的过程。固化粘合剂的步骤包括使热固性粘合剂交联和使热塑性粘合剂固化的步骤。
一种或多种粘合剂可在纤维垫干燥前或干燥后，以直接涂布在纤维垫上的方法而不是以混合在淤浆中的方式涂到增强纤维上。所采用的粘合剂体系是适用于将增强纤维粘结在一起，以使该纤维垫具有明显的抗平面伸长性，并至少在纤维垫被衬入弹性铺地织物片材中作为中间层时，仍允许有显著的平面压缩位移。
根据本发明的详细说明和附图，本发明的目的、特征和优点是显而易见的。
附图的简要说明
图1是根据本发明一个实施方案的非织造纤维垫的透视图；以及
图2是根据本发明一个实施方案用来制造图1非织造纤维垫的多种不规则状玻璃纤维中一根纤维的透视图。
实施本发明的模式
虽然本文是依据制造乙烯基铺地织物的特定实施方案来说明本发明，但对本领域技术熟练人员来说，在不违背本发明精神的前提下能进行各种变更、调整以及替换，这是显而易见的。因此，本发明范围只是由附后的权利要求书限定的。
参看图1，在本发明的一个实施方案中，提供了特别适用在常规乙烯基铺地织物中作中间层的非织造玻璃纤维垫10。该例证性纤维垫10完全由玻璃制的增强纤维12构成，或者如下面另一个实施例中所述的由玻璃制的纤维12与合适的合成材料或非玻璃材料制的纤维12的混合物构成。本文所用名词玻璃是指包括任何玻璃质矿物材料，如岩石、矿渣和玄武岩以及传统玻璃。本文所用名词合成的是指包括具有合适增强特性的任何人造材料，如由聚酯、arramed、聚(亚苯基硫醚)和其它适用的聚合物以及碳化硅(SiC)制的纤维。
将不规则状玻璃纤维14短切或用其它方法切成较短的、长度不等的纤维，以制得卷曲状纤维16、半卷曲状纤维18和甚至较直的或稍弯曲的纤维20，通过采用由这种纤维制得的增强纤维12已经制得了令人满意的纤维垫10。图2所示的是一段具有代表性的不规则状长玻璃纤维14及其二维投影22，该图具体说明了不规则形状或其沿长度旋转的情况。这种不规则状长玻璃纤维14以及制造这种纤维的方法已公开在美国专利5431992和1994年9月21日提出申请的申请号为08/310183，标题为不规则状双组分玻璃纤维的加工方法及其制品的专利申请中，这两篇专利的公开内容已全部列入本文供参考。图2所示的一段不规则状纤维14以虚线(以虚线24表示)分成呈卷曲状的纤维16、半卷曲状纤维18和稍弯曲的纤维20这样三种代表性的形状。
每根由不规则状纤维14制成的玻璃增强纤维12的粗度为约5微米-约15微米，实际长度为0.5英寸(12.7毫米)-约2.0英寸(50.8毫米)。每根由玻璃制的卷曲状纤维16至少有一个或多个外径为约0.25英寸(6.35毫米)-约1.0英寸(25.4毫米)的卷曲圈。
采用聚合物粘合剂体系将增强纤维12粘结在一起形成片材(图中没有显示)，这种粘合剂体系可包括初次粘合剂和二次粘合剂。该初次粘合剂至少能使增强纤维12充分地粘结在一起，以便后续以在线加工将其加工成片材或卷成卷材以备后续离线加工成非织造纤维垫10。可以采用的初次粘合剂包括微粒状(如聚(乙烯醇)粉)或纤维状(如由氯乙烯共聚物或共聚聚酯制的)热塑性聚合物粘合剂或两者的混合物。这些热塑性粘合剂至少部分是以热熔方式使增强纤维粘结在一起。二次粘合剂保证增强纤维12之间充分粘结以使纤维垫10具有显著的抗平面伸长性而仍允许有明显的平面压缩位移。除下面公开的这种两单元(two-part)粘合剂体系的实际例子外，据信，按照与美国专利申请08/619785(申请日期1996年3月20日，标题为湿法成网非织造纤维垫及其制造方法，该专利中请已转让给本申请同一受让人，受让人案号为No.23724A,并同时提出申请)所公开的粘结纺织用玻璃纤维的相同方法(即同样用两单元粘合剂体系)将本发明玻璃增强纤维12粘结在一起会制得具有较低抗平面压缩性的纤维垫10。所述中请的公开内容已全部列入本文供参考。
另一方面，聚合物粘合剂体系可以是单一粘合剂，这种单一粘合剂适用将增强纤维12粘结在一起，以便使成形的纤维垫10成为一种适用作增强弹性铺地织物片材的基材，如用作乙烯基地面织物的中间层。用于将纤维粘结在一起的单一粘合剂体系的实例是一种包含可固化弹性体的水性组合物(如公开在美国专利4849281中的)经除去水分而制得的弹性体粘合剂。所述专利公开内容已全部列入本文供参考。据信，按照与公开在美国专利4849281中的粘结玻璃纤维混合物(即，玻璃棉纤维和纺织用纤维)相同的方法(即同样用两单元粘合剂体系)将本发明玻璃增强纤维12粘结在一起也可制得具有良好的平面压缩性的纤维垫10。
据认为，纤维垫10中增强纤维12的含量为约50％～约95％(重量)，而纤维垫10中粘合剂含量为约5％(如只用单一粘合剂时)至约50％(重量)(如用两种或两种以上粘合剂时)。纤维垫10中增强纤维12的含量可以为约50％-约95％(重量)，而其余为粘合剂，甚至当增强纤维12全部是玻璃纤维时。
本发明的纤维垫10可以利用众所周知的湿法成网非织造技术来制造。在下面每一实施例中，纤维垫10的制造过程是这样的：首先是按0.5英寸(12.7毫米)的切断间距切出多种不规则状玻璃纤维14以形成长度不等(如通常约0.5英寸(12.7毫米)至约2.0英寸(50.8毫米))的随机形状增强纤维12。这些随机状玻璃增强纤维12包括卷曲状纤维16、半卷曲状纤维18以及较直的或稍弯曲的纤维20。将该随机状玻璃增强纤维12与任何其它类型增强纤维混合成为水性介质或淤浆。然后，例如采用任何适用的方法使淤浆脱水，使该增强纤维12从水性介质中分离出来成为湿法成网非织造基网或基垫。这类方法在本技术领域中是众所周知的，因此本文不再详述。众所周知的湿法成网非织造方法和设备的实例可参见美国再颁专利Re 31124，其公开内容已全部列入本文供参考。
玻璃增强纤维12上至少涂布有一种热塑性粘合剂或热固性粘合剂。将湿法成网基垫进行干燥处理，并使粘合剂固化以成形为非织造纤维垫10。可用本技术领域众所周知的任何适当方法将粘合剂涂布在湿法成形的基垫上。将微粒状、纤维状或两者兼有的热塑性初次粘合剂混入淤浆中并加热，例如在湿法成网基垫干燥期间进行加热，以使至少部分粘合剂微粒和粘合剂纤维在增强纤维12上热熔化。二次粘合剂可在湿法成网纤维垫于初始干燥前或者在干燥后涂布在增强纤维上。例如，可将二次粘合剂喷洒在或者倾注在该基垫上，并在基垫下方抽真空将过量的粘合剂除去。
可采用任何适用的方法使纤维垫上粘合剂充分固化，(如果必要，干燥粘合剂的各组分)并形成具有适应于制造纤维垫10所需的热抗拉强度的玻璃纤维垫10，但没有兼顾到纤维垫10所要求的压缩性。根据所采用的粘合剂，或者用使热固性粘合剂交联的方法和/或用使热塑性粘合剂固化的方法来达到粘合剂的固化。干燥和固化步骤可分别在不同时间进行，或可同时进行。
下列实施例说明制造根据本发明的非织造玻璃纤维垫10的实际过程。
实施例1
将含有初次粘合剂的白水溶液和由上述(即公开在美国专利申请08/310183中)适宜不规则状玻璃纤维14短切而成的一定量玻璃增强纤维12相混合制成淤浆。将75升0.35％阴离子聚丙烯酰胺粘度调节剂(如由Allied Colloids，萨福克，弗吉尼亚州，制造的、产品牌号为Percol156)混入总体积为约5000升的水中得到粘度为1.8厘泊的白水溶液。在第一混合槽中装有约500升白水、400克作为初次粘合剂的粉状聚(乙烯醇)以及3600克已短切成长度为12.5毫米的作为增强纤维的不规则状玻璃纤维14。缓慢搅拌该混合物30分钟，然后将混合物转移至第二混合槽中。再添加补充的白水使总体积达2000升，在较强烈地搅拌混合物5分钟后将混合物泵入一台常规湿法成网机中。调整所得稠浆物流至适于以30英尺/分钟(9.1米/分钟)的线速度成形为基准重量为50克/米2的基网或基垫。多余的水经位于沿湿法成网机的成形区的真空抽吸缝用众所周知的技术与设备在运载基垫的常规金属丝输送机下方被抽走。在饱和浸渍器区域不再向基垫涂布补充粘合剂。所得的基垫在设定温度为385°F(196℃)的烘箱中进行干燥，干燥后的基垫的强度足以能用卷绕架卷绕成卷材或者能进一步在线加工成非织造纤维垫。
按照该方法制得基垫后，或以退卷或以在线直接将基垫置于饱和浸渍器区域中并以溢流堰涂敷粘合剂的方法进行二次粘合剂的处理。过量的粘合剂经真空抽吸缝抽去，使基垫上干燥粘合剂量为约10克/米2。例如，二次粘合剂是一种羧化的苯乙烯-丁二烯乳胶，如Dow Chemical(米兰，密歇根州)制造的品牌为Dow Latex 485的羧化苯乙烯-丁二烯乳胶，该乳胶是经2％(重量)的甲基化三聚氰胺-甲醛树脂(如CytecIndustries，(西帕特森，新泽西州)制造的品牌为Cymel 327改性的。该纤维垫和粘合剂以30英尺/分钟(9.1米/分钟)的线速度在设定为375°F(191℃)的烘箱中分别干燥和固化。总的粘合剂固含量为约13％。制得的非织造玻璃纤维垫10适于制造乙烯基铺地织物用的基材。
实施例2
本实施例的基垫是按与上述实施例1相同的方法制备的，只是在第一混合槽中装入500升白水、约280克粉状聚(乙烯醇)和1080克纤维状氯乙烯共聚物粘合剂(如由Wacker AG,Munich，德国，制造的MP纤维)的初次粘合剂体系以及2640克短切长度为12.5毫米的不规则状玻璃纤维14。纤维状氯乙烯粘合剂置于第一混合槽中前，先在水力打浆机(即高剪切搅拌系统)中用60升白水预分散1分钟。按此方法制成基垫后，按上述实施例1方法用二次粘合剂处理、进行干燥及固化以制成另一种适于制造乙烯基铺地织物用基材的非织造玻璃纤维垫10。
实施例3
本实施例的基垫是按与上述实施例2相同的方法制备的，只是在第一混合槽中装入500升白水、约280克粉状聚(乙烯醇)和600克纤维状氯乙烯粘合剂的初次粘合剂体系以及3120克短切长度为12.5毫米的不规则状玻璃纤维14。纤维状氯乙烯粘合剂置于第一混合槽中前，先在水力打浆机中用60升白水预分散1分钟。按本方法制成基垫后，按上述实施例1方法用二次粘合剂处理、进行干燥及固化以制成另一种适于制造乙烯基铺地织物用基材的非织造玻璃纤维垫10。
实施例4
上述1-3实施例涉及在饱和浸渍二次粘合剂前先干燥纤维基网。本实施例涉及直接用二次粘合剂浸渍湿的纤维基网。在本实施例中，将4000克短切长度为12.5毫米的不规则状玻璃纤维14分散在2000升白水中，而不添加初次粘合剂。90％(重量)羧化的苯乙烯-丁二烯乳胶与10％(重量)甲基化三聚氰胺-甲醛树脂混合物(以固体量计混合)作为二次粘合剂，按总固体含量为约15％(重量)涂布在湿的纤维垫上。湿的纤维垫在温度设定为425°F(218℃)的烘箱中干燥及固化后，得到了基准重量为60克/米2的纤维垫10，粘合剂增加的重量为17％。
实施例5
按照与实施例4相同方法制备另一种纤维垫10，只是增强纤维是3200克短切长度为12.5毫米的不规则状玻璃纤维14与800克1.7旦×12.5毫米聚对苯二甲酸乙二醇酯纤维(如由Hoechst-Celanese，夏洛特，北卡罗来纳州，制造的100型纤维)的纤维共混物。
当随机卷曲的和半卷曲的增强纤维12取代如美国专利4849281中所述结构中的羊毛纤维时，在提高其结构的强度和加工性的同时也可改善其压缩性。当增强纤维12是上述(即美国专利申请08/310183所述的，其公开内容已在上文列入供参考)不规则状玻璃纤维14的短切段时上述结果是特别确实的。这些短切的不规则状玻璃纤维以全部或部分取代时，也会有较美国专利申请08/619785(申请日期1996年3月20日，标题为湿法成网非织造纤维垫及其制造方法，该专利申请已转让给本申请同一受让人，受让人案号为23724A，并同时提出申请，该专利申请内容已在上文列入供参考)中公开的纺织用玻璃纤维制的纤维垫低的抗平面压缩性。
从上面公开的本发明的一般原理和上述详细说明，本领域技术熟练人员对本发明可有各种不同的变更这一点是会容易理解的。例如，大家都知道，本发明不必限于采用玻璃制的增强纤维，也可采用由非玻璃材料制的、部分或全部呈卷曲的或半卷曲状的增强纤维，并且本发明非织造纤维垫用作除乙烯基铺地织物外的弹性铺地织物片材的增强层可能是很理想的。因此，本发明范围应该只受下述权利要求书及其对应范围所限制。

Claims (23)

1．一种湿法成网非织造基垫，该基垫包括：
多种组合成片材的增强纤维，所述增强纤维包括呈半弯曲状的纤维；及
至少一种粘合剂，该粘合剂用来将所述增强纤维粘结在一起形成片材，以便至少能使所述基垫可后续加工成适用作增强一种弹性铺地织物片材的纤维垫。
2．根据权利要求1的基垫，其中所述增强纤维基本上全部由玻璃制成。
3．根据权利要求1的基垫，其中所述增强纤维包括玻璃纤维与合成纤维。
4．根据权利要求1的基垫，其中所述粘合剂包括至少一种呈部分熔融微粒状和部分熔融纤维状形态的热塑性聚合物粘合剂。
5．一种增强弹性铺地织物片材用的湿法成网非织造纤维垫，所述纤维垫包含：
多种构成片材的增强纤维，所述增强纤维包括至少呈半卷曲状的纤维；及
至少一种聚合物粘合剂，该粘合剂用来将所述增强纤维粘结在一起，以便制成可用来增强弹性铺地织物片材的所述纤维垫。
6．根据权利要求5的纤维垫，其中所述纤维垫适用作乙烯基铺地织物的中间层。
7．根据权利要求5的纤维垫，其中所述增强纤维还包括呈卷曲状的纤维，而每根卷曲纤维至少有一个卷曲圈。
8．根据权利要求7的纤维垫，其中所述半卷曲纤维与所述卷曲纤维在整个片材上是随机配置的。
9．根据权利要求7的纤维垫，其中每根所述卷曲纤维是由玻璃制的且所述卷曲的外径为约0.25英寸(6.35毫米)-约1.0英寸(25.4毫米)。
10．根据权利要求7的纤维垫，其中所述增强纤维还包括稍弯曲纤维，所述稍弯曲纤维、所述半卷曲纤维及所述卷曲纤维都是玻璃纤维，而所述片材包括约50％-95％(重量)的所述玻璃纤维。
11．根据权利要求7的纤维垫，其中所述半卷曲纤维和所述卷曲纤维都是玻璃纤维，而每根玻璃纤维的粗度为约5微米-约15微米，长度为约0.5英寸(12.7毫米)-约2.0英寸(50.8毫米)。
12．根据权利要求5的纤维垫，其中所述片材包含约50％-约95％(重量)增强纤维和约5％-约50％(重量)的所述聚合物粘合剂。
13．根据权利要求5的纤维垫，其中所述增强纤维还包括至少一种合成纤维、纺织用玻璃纤维、玻璃棉纤维及已经切成较短的不规则状玻璃纤维。
14．根据权利要求5的纤维垫，其中所述聚合物粘合剂包括一种初次粘合剂，该初次粘合剂至少能使所述增强纤维充分地粘结在一起，以使所述片材可后续加工成可用作增强弹性铺地织物片材的纤维垫。
15．根据权利要求14的纤维垫，其中所述初次粘合剂包括至少一种呈部分熔融微粒状和部分熔融纤维状形态的热塑性聚合物粘合剂。
16．根据权利要求14的纤维垫，其中所述聚合物粘合剂还包括一种二次粘合剂，该二次粘合剂能使所述增强纤维充分地粘结在一起，以使所述纤维垫有显著的抗平面伸长性并仍允许有明显的平面压缩位移，至少在所述纤维垫衬入弹性铺地织物片材时是这样的。
17．根据权利要求5的纤维垫，其中所述聚合物粘合剂是一种单一粘合剂，该粘合剂能使所述增强纤维充分地粘结在一起，以使所述纤维垫有显著的抗平面伸长性并仍允许有明显的平面压缩位移，至少在所述纤维垫作为中间层衬入弹性铺地织物片材中时是这样的。
18．一种成形增强弹性铺地织物片材适用的非织造纤维垫的方法，所述方法包括如下步骤：
将多种不规则状纤维切成长度不等的随机状纤维；
提供包含至少该随机状纤维的增强纤维淤浆；
将该淤浆成形为湿法成网增强纤维非织造纤维垫；
将至少一种粘合剂涂敷在增强纤维上；
干燥湿法成网纤维垫；及
固化粘合剂。
19．根据权利要求18的方法，其中所述方法还包括由至少两种具有不同热膨胀系数的不同玻璃成形为多种不规则状纤维的步骤。
20．根据权利要求18的方法，其中所述方法还包括如下步骤：
由至少两种不同玻璃成形为多种不规则状纤维；
将合成纤维、纺织用玻璃纤维及玻璃棉纤维中的至少一类纤维切成多种短纤维；及
所述提供淤浆步骤包括提供还含多种短纤维的增强纤维淤浆。
21．根据权利要求18的方法，其中所述将粘合剂涂敷在增强纤维上的步骤包括如下步骤：
在淤浆中有至少一种热塑性初次粘合剂，其中初次粘合剂至少呈微粒状和纤维状之一形态，
加热初次粘合剂，以使该初次粘合剂至少部分熔入增强纤维中；及
将可固化的二次粘合剂涂敷在增强纤维上；
其中所述干燥湿法成网纤维垫步骤包括至少在二次粘合剂涂敷之后干燥纤维垫，且所述固化粘合剂步骤包括至少是一种使该粘合剂发生交联和使该粘合剂固化的步骤。
22．根据权利要求21的方法，其中所述干燥湿法成网纤维垫步骤包括只在二次粘合剂涂敷后对纤维垫进行干燥。
23．根据权利要求18的方法，其中所述将粘合剂涂敷在增强纤维上的步骤还包括将粘合剂涂布在纤维垫上使增强纤维粘结在一起，以便提供具有明显的抗平面伸长性和较低的抗平面压缩位移的纤维垫。
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