CN1285787C - 复合织物 - Google Patents

复合织物 Download PDF

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Publication number
CN1285787C
CN1285787C CNB998162655A CN99816265A CN1285787C CN 1285787 C CN1285787 C CN 1285787C CN B998162655 A CNB998162655 A CN B998162655A CN 99816265 A CN99816265 A CN 99816265A CN 1285787 C CN1285787 C CN 1285787C
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Prior art keywords
fabric
cord ply
layer
composite fabric
composite
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Expired - Fee Related
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CN1371436A (zh
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菲利普·W·布莱克莫尔
戴维·L·斯潘顿
道格拉斯·W·莱文
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Saint Gobain Adfors America Inc
Saint Gobain Adfors Canada Ltd
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Bay Mills Ltd
Saint Gobain Technical Fabrics America Inc
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    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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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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    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
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  • Diaphragms For Electromechanical Transducers (AREA)
  • Materials For Medical Uses (AREA)
  • Glass Compositions (AREA)
  • Treating Waste Gases (AREA)
  • Chimneys And Flues (AREA)

Abstract

本发明的一种轻质、高强度的复合织物(110)适宜用作毡垫、屋面材料和膜，以及需采用坚固织物的其它产品。该复合织物(110)包含一无纺材料层(116)，它设于一低收缩经线层(112)和一低收缩纬线层(114)之间。各层缝合或针织在一起，并且最后的织物(110)可涂覆有一层树脂或浆料(122)以防止织物各层之间滑动，并使该织物(110)具有一定的硬度。该织物可制造成片状，或更好地，做成卷状，织物(110)可以适于最终用途需要的材料如沥青材料涂覆，在这里，织物(110)当作一种备用屋面材料膜或其他高强度的织物产品。

Description

复合织物
发明领域
本发明一般涉及织物，特别涉及适宜用作毡垫、屋面材料膜，以及需采用坚固织物的其它产品的轻质、高强度的复合织物。
发明背景
毡垫、屋面材料膜和其他产品一般需要采用柔韧、坚硬且耐用的织物。过去，这种织物典型地用编织和无纺的天然、人造织物做成，比如大麻纤维、黄麻纤维、尼龙、聚酯及类似物。当用作毡垫时，织物一般涂覆胶乳或类似材料，而当用作屋面材料膜时，织物可涂覆沥青材料。
在这些织物中，一些可认为是复合结构。比如，许多屋面材料膜包含一编织材料层和一无纺材料层。编织材料一般具有强度和耐用度，无纺材料则防止屋面材料膜中的沥青渗入，和粘合剂在毡垫生产过程中从毡垫流出。一些生产者用胶把无纺材料粘合到编织材料上，然而，在这类产品中粘合失效百分率较高。其他生产者则通过把无纺材料缝合或针织到编织材料上来克服了这一问题。
例如，在专利号为5,474,838和5,569,430的美国专利中，记叙了包含增强材料的屋面材料膜、该增强材料基本上由其上缝合或针织有一由聚酯和/或尼龙制成的热塑性人造短纤维无纺层的玻璃纤维稀松平纹织物组成。无纺材料是用具有缝合能力的马利莫或纬向嵌入缝编机上缝合或针织到玻璃纤维稀松平纹织物上的。然后，复合织物以沥青材料浸泡，从而生产出最终的屋面材料膜产品。这样制备的复合增强材料会导致织物在结构上“不均衡”。这种结构的缺点随着无纺材料重量的增加，以及当增强材料暴露在高温下，如在屋面材料膜制造过程的最后阶段，即增强材料被热的沥青浸透时而变得逐渐明显。
另外，当浸透的屋面材料膜安装在屋面材料时，在安装膜之前，屋面材料可能覆盖一热的沥青粘性涂层。一旦膜被安装好，在膜的上表面可加入热和/或涂上第二层热的沥青材料。但是，如果复合织物中的无纺材料有足够的重量，并且暴露在足够热的沥青中，热塑性的无纺材料可能会有所收缩。而另一方面，玻璃纤维稀松平纹织物织物在尺寸上保持基本不变。与平纹织物相连的无纺材料的不同的收缩性可导致膜卷曲，或者，可导致膜在经向或纬向变形，或两个方向上都变形。这样，根据专利号为5,474,838和5,569,430的美国专利中记载的方法而制造的屋面材料膜用在屋面材料表面时，在美学效果上可能会比想要的差一些。甚至更重要的是，它们可能不会均匀地粘在屋面材料，从而产生缝隙，可能使水、脏物、污染物和其他对屋面材料建筑有害的空气生成物进入。
因此，对于适合于作屋面材料膜、毡垫和其他用途的复合织物来说，它具有轻质、高强度、结构均衡，并且高温下抗变形的优点。
发明简述
本发明提供了一种适宜用作毡垫、屋面材料和膜，以及需采用坚固织物的其它产品的轻质、高强度的复合织物。该复合织物包含一无纺材料层，它设于一低收缩率经线层和一低收缩率纬线层之间。各层缝合或针织在一起，并且最后的织物可涂覆有一层树脂或浆料以防止织物各层之间滑动，并使织物具有一定硬度。根据目前较好的实施方式来看，经线层和纬线层是玻璃纤维绳，无纺材料可包括天然和/或人造纤维材料，比如玻璃或热塑性纤维丝、人造纤维、棉线、亚麻线(亚麻织物)、苎麻纤维、纸、木浆或它们的混合物。该织物可制造成片状，或更好地，做成卷状，并且可被适于最终用途的材料，如沥青材料涂覆，这种织物可作为一种备用的屋面材料膜或一种高强度的织物产品。
本发明的其它细节、目的和优点将由以下目前该发明的优选实施方式和实现本发明优选方法的详细描述而更为显见。
附图简述
结合其中的附图，本发明将由以下所示的优选实施例的详述而更为显见，该实施例仅为例举：
图1是在现有技术中的复合织物的分解图；
图2是根据本发明制造的复合织物的分解图；以及
图3是一种包含图2中复合织物的屋面材料膜的正面剖视图。
发明的详细描述
首先，如图1中所示一种常规结构的复合织物。标号10标示的织物一般描述了由Milliliken Research Corporation of Spartanburg S.C.制造的复合织物。织物10含有玻璃纤维稀松平纹织物，其包括基本上平行的经向(或轴向(machine direction))玻璃纤维绳第一层12，和基本上与第一层12呈垂直方向延伸的纬向(或交叉向(cross-machinedirection))玻璃绳第二层14。织物10还包括由聚酯人造短纤维做成的无纺材料第三层16，无纺层16是通过图中未示出的缝线缝合到第二层14的表面，即在第一层12的相对一侧。可以确信，织物10表示了前面所述的、披露在专利号为5,474,838和5,569,430的美国专利中的屋面材料膜增强织物。
图2和图3分别描述了本发明中目前优选实施例中的复合织物和包含了本发明中织物的屋面材料膜。图2中标号110所指的织物包含了基本上平行的经线第一层112、纬线第二层114，以及设于第一和第二层112和114之间的无纺材料第三层116。第二层114可以做成基本上平行线绳，或做成记载于图1织物10中的第二层14略呈锐角的线绳(相对于第一层12的经线)。
第一层112和第二层114的线绳都是优选采用低收缩的纱线或粗线制作而成。并且优选采用当暴露在宽温度范围内时能保持它们的尺寸稳定性和完整性的高弹性模数的纤维材料。这些材料比如包括(不限)：公知为Kevlar的聚(对亚苯基对苯二甲酰胺)的聚酰胺纤维、称作Nomex的邻亚苯基对苯二甲酰胺；超低收缩聚酯、尼龙、玻璃纤维以及它们的混合物。目前，适合用作第一层112和第二层114的线绳的优选材料是约150s(15000yds/lb)-约18(1800yds/lb)的玻璃纱线，或约68特克斯-约735特克斯的粗纱。
目前适合用作无纺材料层116的优选材料包括(不限)：玻璃、聚酯、尼龙、人造纤维、棉线、亚麻线、苎麻纤维、纸、木浆，以及它们的混合物制成的人造短纤维或连续纤维。例如，合适的无纺层116可包括纸，比如薄纱纸、梳理纤维网(包括梳理后化学粘接以及梳理后热粘接)、纺织粘合体、约0.5到约1.5盎司/平方码的聚酯和/或人造短纤维的湿直纹织物(wet laid webs)和干直纹织物(air laid webs)、或约0.7到约2.3lb/100ft2的玻璃丝，人造纤维、棉线、亚麻线(亚麻织物)、苎麻纤维，木浆和它们的混合物。无纺材料层116的作用是帮助织物110保留在织物成型后涂在其上面的涂覆材料，如以下结合图3中所述的沥青材料。
织物110可以通过能够按所需的顺序装配112、114和116层的任何合适方法或装置制作。目前适合装配织物110的优选装置是Liba经线针织机。在机器中，经线层112被做成并在拉力下拉直，无纺层116嵌在经线层下，接着，纬线层114置于无纺层下。织物安装是在图中未示出的绳夹舌板中进行，然后用缝合线118(图3)缝合在一起。缝合可采用任何传统的缝合或针织构型方式。缝合纱线118可以是任何合适的天然和/或能可靠地固定织物110中各层的合成纱线或合成丝。目前较好的缝合纱线是大约40丹尼尔到约250丹尼尔(更优选采用约150丹尼尔)的聚酯、尼龙、聚酯/尼龙混合物或任何常规的、轻质高强度的合成纱线。
织物110在装配好之后要涂上一层能提供织物低到中等硬度的树脂、上胶材料或其它材料的薄涂覆层。该涂剂“锁定”了112、114和116层的位置，一防止它们相互滑动，有利于卷形织物的成型和储藏，并可提高织物的可操作性。
由于无纺材料层116设置在防收缩的经线第一层112和纬线第二层114之间，而不是在平纹织物的一边或另一边，在结构上织物110是均衡的复合织物。因此，它能抗卷曲、弯曲或其他在任何实际应用及可能希望用到的任何温度范围内的变形，无论无纺层116有多重。此用途的一个例子见图3。图中，可以看到一种织物增强产品120中包含了封埋在一种天然或合成的、适宜用作屋面材料及毡垫等应用的聚合物涂层或浸泡材料122里的织物110，这种聚合材料可包括(不限)沥青、改性的沥青、聚氯乙烯、聚氯乙烯增塑溶胶、乙烯-丙烯二烯单体、氯代磺化聚乙烯、聚异丁烯和氯化聚乙烯。
在产品120的制造过程中，复合增强织物110可能被沥青材料浸透来生产一种屋面材料膜。实现该目的，织物要传送通过一个装有采取原有技术中的方法而加热到约275到425(摄氏135℃到220℃)的沥青材料的槽。织物110也可与冷的胶粘剂一起使用，这样可使它在织物涂覆层过程中是或屋面材料膜120安装到屋面材料的过程中不会直接与热的涂覆物接触。产品120可以成卷状制造和储藏。并且可以采用额外的沥青材料和/或热源把膜粘合和封接到屋面材料及邻接类似的膜上的方式施用于屋面材料。
织物110装配好之后，希望浸透其他基本上流体不可渗透的材料以生产织物增强产品，如屋面材料膜和毡垫。其他的这种浸泡材料可包括(不限)沥青、改性的沥青、聚氯乙烯、聚氯乙烯增塑溶胶、乙烯-丙烯二烯单体(EPDN)、氯代磺化聚乙烯、聚异丁烯和氯化聚乙烯。
本发明已如上详述，应当理解的是其仅用于说明本发明，而且本领域的普通技术人员在不脱离本发明的精神和所附权利要求的范围可对本发明作出变换。

Claims (9)

1.一种包含封埋在聚合物材料中之复合织物的织物增强产品，该复合织物(110)包括第一线绳层(112)、第二线绳层(114)以及设于所述第一线绳层和第二线绳层之间的中间层(116)，
所述第一线绳层仅具有经向经线绳，所述第二线绳层仅具有横向于经向的纬线绳，所述中间层由抗渗露无纺材料构成，
所述中间层(116)的抗渗露无纺材料与所述第一线绳层(112)和第二线绳层(114)被缝合或针织到一起形成所述复合织物之前是相分离的；以及
所述复合织物(110)具有薄涂覆层，其与所述复合织物一起埋入所述聚合物材料中，
其中所述薄涂覆层向所述织物提供低到中等硬度。
2.权利要求1所述的织物增强产品，其中在所述第一线绳层(112)和所述第二线绳层(114)中的线绳都是由低收缩率材料制成。
3.权利要求2所述的织物增强产品，其中的低收缩率材料选自聚(对亚苯基对苯二甲酰胺)的聚酰胺纤维、邻亚苯基对苯二甲酰胺、超低收缩聚酯、尼龙、玻璃纤维或它们的混合物。
4.权利要求1所述的织物增强产品，其中所述中间层(116)是由人造短纤维或连续纤维制成，这些纤维选自玻璃、聚酯、尼龙、人造纤维、棉线、亚麻线苎麻纤维、纸、木浆，或它们的混合物。
5.权利要求1所述的织物增强产品，其中聚合物材料选自沥青、改性沥青、聚氯乙烯、聚氯乙烯增塑溶胶、乙烯-丙烯二烯单体、氯代磺化聚乙烯、聚异丁烯和氯化聚乙烯。
6.权利要求1所述的织物增强产品，其中封埋于所述聚合物材料中的具有薄涂覆层的复合织物(110)适于用作一种屋面材料膜。
7.权利要求1所述的织物增强产品，其中封埋于所述聚合物材料中的具有薄涂覆层的复合织物(110)适于用作毡垫。
8.权利要求1所述的织物增强产品，其中所述薄涂覆层包括树脂或上胶材料。
9.权利要求1所述的织物增强产品，其中所述薄涂覆层锁定所述各层并防止各层彼此间的相对滑移运动。
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