CN1307340C - 使用粘合剂的无纺叠层复合材料 - Google Patents

使用粘合剂的无纺叠层复合材料 Download PDF

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Publication number
CN1307340C
CN1307340C CNB008110182A CN00811018A CN1307340C CN 1307340 C CN1307340 C CN 1307340C CN B008110182 A CNB008110182 A CN B008110182A CN 00811018 A CN00811018 A CN 00811018A CN 1307340 C CN1307340 C CN 1307340C
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CN
China
Prior art keywords
laminated material
synthetic fiber
nonwoven layers
glass fibre
nonwoven
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CNB008110182A
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English (en)
Other versions
CN1646762A (zh
Inventor
W·戈罗
M·绍普斯
W·塞斯
R·施瓦尔兹
M·纳戈尔
W·戈雷瑟
M·杰纳
J·安明戈
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johns Manville
Original Assignee
Johns Manville International Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from DE19935408A external-priority patent/DE19935408B4/de
Priority claimed from DE19935531A external-priority patent/DE19935531C2/de
Priority claimed from DE19950057A external-priority patent/DE19950057B4/de
Priority claimed from DE19952432A external-priority patent/DE19952432B4/de
Priority claimed from DE19955713A external-priority patent/DE19955713C1/de
Priority claimed from DE19955730A external-priority patent/DE19955730C2/de
Application filed by Johns Manville International Inc filed Critical Johns Manville International Inc
Publication of CN1646762A publication Critical patent/CN1646762A/zh
Application granted granted Critical
Publication of CN1307340C publication Critical patent/CN1307340C/zh
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • 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
    • B32B5/06—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 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/156—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is calendered and immediately laminated
    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
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    • D—TEXTILES; PAPER
    • 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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Abstract

本发明涉及一种无纺叠层材料及其制备方法。该叠层材料包括至少一层针刺复合有至少一层热收缩合成纤维无纺层的预固结无纺层，所述预固结无纺层含有玻璃短纤维。上层无纺层的一部分纤维穿过玻璃纤维无纺层，有可能穿过下层的合成纤维无纺层。该叠层材料含有一固结粘合剂。

Description

使用粘合剂的无纺叠层复合材料
发明背景
1、发明领域
本发明涉及一种制备由至少一层无机短纤维的无纺层和至少一层有机合成纤维无纺层组成的多层叠层材料的方法，所得产品及其用途。
2、相关技术的描述
由粘合织物组成的叠层材料被用于例如居住和商用建筑的墙壁和地板覆盖材料。特别是被用于屋面毛毡和保温材料，在此叠层材料被用作支撑材料。粘合的织物在沥青化屋面毛毡和膜中作为载体找到特殊应用。当然，这些叠层材料也可以涂覆其它材料例如聚氯乙烯。
由至少一层无纺合成纤维和无纺无机材料制成的多种叠层材料在工业领域是公知的。例如，EP0176847A2公开了一种由人造纤维特别是聚酯纤维无纺层和无机纤维无纺层组成的叠层材料。人造纤维无纺层以及无机纤维无纺层是预固结的，然后通过针刺粘结在一起。
欧洲专利文献0242524B1提议了在纵向上增加增强纱线，其中的无纺材料是由无机纤维组成。实施例B公开了通过添加本领域公知粘合剂实现的复合材料的最终固结。
欧洲专利文献0379100B1公开了由长丝无纺织物和玻璃纤维无纺织物制成的叠层材料，其中叠层材料是这样制备的：首先预固结玻璃纤维无纺织物，然后针刺该无纺织物和合成纤维无纺织物。随后，最终固定是使用不合聚合物的三聚氰胺甲醛预缩聚物水溶液完成的，所述预缩聚物中三聚氰胺/甲醛摩尔比为1∶1.0-1∶3.5，其中溶液中加入了大于0.5-5wt％的常用促进剂。
类似的双层叠层材料公开在南非文献ZA94/02763A中。另外，南非文献特别公开了三层叠层材料，其中玻璃短纤维无纺织物被置于通过针刺初步稳定化了的两层聚酯无纺织物中间，随后这三层又进一步通过针刺方法粘结在一起。聚酯无纺织物的长丝被牵拉过玻璃短纤维无纺织物。
DE19521838A1公开了密实粘合的织物，它至少由三层组成，为有机纤维织物的中间层的两侧叠置有增强层。优选的是，这两层增强层是由无机纤维制成的。其中它还提议了通过针刺和/或通过热或化学粘合剂粘合的方法增强粘合织物。
EP0603633B1公开了至少一层固结的纺丝-叠置(spun-laid)无纺层、玻璃纤维稀松无纺布层和金属箔的阻燃叠层材料。其中描述的叠层材料同样可以包括以三明治方式置于两层聚酯长丝无纺层中间的玻璃纤维稀构无纺层，另外还包括上述金属箔。稀松无纺层的玻璃纤维是玻璃线，即玻璃的复丝线。玻璃线可以是出厂捻(producer twist)，但同时也可以是未捻丝束。该层可以通过机械方法固结(例如通过针刺)，或者通过化学粘合剂固结(例如聚乙烯醇或丁二烯苯乙烯共聚物)。热塑性粘合剂，特别是纤维状的热塑性粘合剂同样可以使用。
其它的多层叠层材料公开在欧洲专利文献EP0187824B1中，其中特别包括叠置在有机纤维上的纺织纤维层。该叠层材料用基于氟聚物分散体的粘合剂处理。
欧洲专利文献EP0403403公开了多层结构，其中除了玻璃纤维无纺织物之外，还使用了聚酯短纤维无纺织物。其中的玻璃短纤维需要非常准确地平行于表面排列。
欧洲专利文献EP0572891A1公开了无纺织物和稀松无纺织物的叠层材料，除了金属箔之外，它具有与EP0603633B1中所述类似的结构。这些叠层材料同样用粘合剂处理。
欧洲专利文献EP0806509公开了一种支撑层，其中含有一种织物和一种增强体，其中增强体用于抵消力，特别是伸长为0-1％。其中，也建议使用粘合剂。
与上述叠层材料有关的缺点包括缺乏力学强度(即脱层)、尺寸稳定性、撕裂传播和阻燃性。
为了满足屋顶、密封、地板和保温业的要求并克服有关技术领域的缺陷，本发明的目的之一是提供由至少一层有机合成纤维无纺层和无机短纤维无纺层组成的粘合织物或叠层材料，它是以快速便捷的方式制备的。
本发明的另一个目的是提供一种叠层材料，它是通过使用粘合剂进行最终固结的，并提高了机械强度。
本发明的又一个目的是利用该叠层材料作为支撑网，特别是具有最小“香蕉弯曲效应”的沥青网。
本发明的又一个目的是提供能够用沥青或其它合成材料饱和的叠层材料，并用作屋面毛毡、密封膜等。
本发明的又一个目的是提供一种制备叠层材料的方法，该叠层材料在沥青化中和沥青化后具有提高的尺寸稳定性，并具有好的阻燃性。
本发明的又一个目的是提供一种叠层材料，该叠层材料作为沥青化网或膜时，同玻璃纤维无纺层的比例相比，合成纤维无纺织物比例可以减小而不使粘合织物产生明显缺陷，并提高了阻燃性。
参考了下面的说明和后附的权利要求之后，本发明的其它目的和方面对本领域技术人员来说将变得显而易见。
发明的简述
根据本发明的叠层材料及其制备方法，可以确定一两层或多层叠层材料，其中该叠层材料是通过使用粘合剂进行最终固结的。
本发明的一个方面提供了一种叠层材料。该叠层材料包括至少一层针刺有至少一层热收缩合成纤维无纺层的预固结无纺层，所述预固结无纺层含有玻璃短纤维。上层的合成纤维无纺层的一部分纤维穿过玻璃纤维无纺层，有可能穿过下层的合成纤维无纺层。该叠层材料含有一固结粘合剂。
本发明的另一方面提供了一种制备两层或多层叠层材料的方法。含有玻璃短纤维的一层或多层无纺衬垫用树脂预固结，然后置于合成纤维无纺层下面或中间，其中合成纤维无纺层和含有玻璃纤维的预固结无纺衬垫通过针刺粘合在一起，结果使上面的合成纤维无纺层中的一部分纤维穿过无纺层，热收缩该合成纤维，使该叠层材料通过使用粘合剂最终固结。
本发明优选实施方式的详细描述
现在，本发明将通过参考其典型的实施方式进行描述。在本发明的第一方面中，至少一层无纺衬垫含有玻璃短纤维且至少一层合成纤维的无纺层作为另一层。本文中定义的衬垫由短纤维(例如玻璃或合成纤维)或一层或多层长纤维组成。两层或多层通过这样的方式针刺粘结在一起，即使合成纤维无纺层中的一部分纤维穿过玻璃纤维无纺层。两层或多层以使合成纤维穿过整个玻璃纤维无纺衬垫的形式针刺粘结在一起。
合成纤维无纺层可以是短纤维，但优选是长纤维。这些长纤维对本领域技术人员来说也被称作“未切断”或连续纤维。短纤维或长丝可以是多组分纤维，特别是本领域公知的双组分纤维。合适的纤维材料可以选自下述聚合物或共聚物：例如聚酯、聚对苯二甲酸乙二酯、聚丙烯、聚酰胺或聚烯烃。优选的是聚丙烯，最优选的是聚对苯二甲酸乙二酯。在典型的实施方式中，合成纤维无纺织物是通过机械、流体动力学、热或压延方法在合成纤维可以整体收缩的温度下预固结。此外，合成纤维无纺织物可以在与玻璃纤维无纺织物粘结之前、预固结之前或之后但优选与玻璃纤维无纺层粘结之前收缩。
当然，该叠层材料可以包括合成纤维的第三层，因此夹在玻璃纤维无纺衬垫中间。当有两层或多层合成纤维无纺层，特别是两层聚酯纤维长丝的无纺层时，优选，无纺层的物质(克/m2)(gsm substance)(即单位面积重量，优选用克/m2表示)之比大约为1∶1-1∶5。优选的是，这些无纺层的物质(克/米2)之比为1∶1-1∶2，并且优选无纺织物在针刺之前没有预固结。
在优选实施方式中，预先制备的玻璃纤维无纺衬垫在与合成纤维无纺织物通过针刺粘结之前用粘合剂预固结。玻璃纤维的直径大约为8-16μm，优选大约10-13μm。纤维的长度大约为8-32mm，优选8-18mm。可以使用的合适粘合剂包括，例如脲甲醛、三聚氰胺甲醛、酚醛、环氧、醋酸乙烯酯、聚氯乙烯、乙烯醇、丙烯酸酯和其它热塑性和热固性树脂。使用的粘合剂的量大约为玻璃纤维无纺织物的5-45wt％，优选10-30wt％。
本领域技术人员容易认识到，高达40％的玻璃纤维可以用其它纤维取代。特别是纤维素基纤维、聚丙烯腈、聚酯、聚酰胺等。
玻璃衬垫可以用干法制备，但优选用湿法制备。因此，玻璃衬垫的物质(克/米2)大约为30-150g/m2。更优选的是，物质(克/米2)大约为50-90g/m2。
随后，将形成的叠层材料通过使用粘合剂最终固结。用于最终固结的合适粘合剂包括脲甲醛、三聚氰胺甲醛。市售丙烯酸酯或苯乙烯粘合剂的用量优选大约为叠层材料的3-35wt％，最优选大约为10-18wt％。除了上述粘合剂之外，还可以使用苯乙烯共聚物、丁二烯、丙烯酸酯和硬塑性粘合剂例如脲和三聚氰胺树脂的混合物。
玻璃纤维无纺层可以包括下述形式的增强体：纵向排列的短纤维纱线、复丝、玻璃的单丝或线、或其它合成材料例如高密度聚乙烯、芳酰胺、聚酯和稀松无纺布形式的其它增强材料。本文中使用的稀松无纺布包括长丝的叠层(laid layer)，以及机织长丝。增强长丝、纱线或稀松无纺布可以与纵向或横向成任意角度排列，例如10-30°。另外，增强材料可以置于之间或其它层中。增强体间隔大约1-35mm排列。线的纤度(titre)大约200-1500分特(dtex)，优选大约300-700分特。本领域技术人员容易理解，分特或特分别是每10000m或1000m长丝的克数的测试单位。
叠层材料可以用在线(on-line)或离线(off-line)方法制备。根据本发明另一个典型的实施方式，用离线方法制备了两层叠层材料。该叠层材料包括预固结的聚酯长丝无纺织物和预固结的玻璃短纤维无纺织物。聚酯无纺织物是通过针刺预固结的。
有机合成纤维无纺织物优选用DE-OS2460755中描述的纺粘方法由聚酯纤维制成，所述文献全部被引用在本文中作参考。优选的是，使用的合成纤维是聚对苯二甲酸乙二酯或共聚酯。因此，针刺预固结是每cm2针刺10-40针(stitch)完成的。预固结长丝无纺层的物质(克/米2)大约为30-350g/m2，优选100-230g/m2。纤维的收缩可以在预固结之前或者任选地预固结之后进行。加热温度为140-220℃，或对应于用于沥青浸渍叠层材料的含沥青的浴的温度。其它预固结方法例如机械方法、流体动力学方法、热方法(例如压延机)也是发明人所设想的，并且也在本发明范围之内。
玻璃纤维无纺层是根据所谓的湿法制备的，其中E级或C级和它们的混合物或其它市售玻璃例如ECR玻璃是用上述脲、三聚氰胺和其它粘合剂树脂预固结的。本领域技术人员容易认识到，高达40％的玻璃纤维可以用其它纤维取代。特别是纤维素基纤维、聚丙烯腈、聚酯、聚酰胺等。
进行湿固定，涂布的涂层大约为5-45％，优选大约10-30％。因此，物质(克/米2)大约为30-120g/m2，优选大约50-90g/m2。另外，例如参考上述实施方式讨论的增强添加剂和纱线也可以加入到玻璃纤维无纺层中。根据5cm宽样品在纵向上测试的应力-应变图所示(施加的应力至少为100N，伸长小于3％，优选小于2.5％)，预固结玻璃无纺层是特别有利的。
将两层预先制成的无纺层叠置并用针刺粘结在一起。为了使部分长丝穿过玻璃纤维无纺层达到合成纤维无纺层相对一侧并可能粘结其上，聚酯长丝是有利的。此后，将叠层材料通过粘合剂最终固结。
在又一个优选的实施方式中，制造了三层或多层的叠层材料。例如，将玻璃纤维层置于聚酯外层，随后在其上叠置第二聚酯层，得到的叠层材料具有至少一层聚酯外层。
离线方法的特征在于，合成纤维无纺织物和玻璃纤维无纺织物是分开制备的。将合成纤维通过将无纺织物通过大约140-220℃的烘箱而进行热处理，以这种方式，随后的处理将不引起纤维和/或无纺织物收缩。然后将这样制备的无纺织物通过针刺与玻璃纤维无纺织物复合。因此，不管使用什么方法，都需要使用粘合剂来固结该层。
在线方法中，玻璃纤维无纺织物是在制备合成纤维无纺织物的过程中引入到叠层材料中的。特别是，首先将一个或几个聚酯长丝帘叠置在移动的输送线上。玻璃纤维无纺织物被置于一层或多层聚酯上，其上任选地叠置其它的聚酯层。聚酯无纺层在复合不同层之前，或任选地之后进行热收缩。
根据优选的实施方式，将玻璃纤维无纺织物通过所谓的在线方法引入到纺粘的聚酯纤维无纺层之间。对应于制成的纤维帘(即合成纤维无纺层)的纺丝束通过管道在移动的沉积面上(例如输送带)纺丝或拉伸。于是，将预先制备的玻璃短纤维无纺层叠置在预固结或没有预固结的聚酯长丝无纺层上，反之亦然。视需要，添加其它的层。在优选实施方式中，制备了具有相同或不同物质(克/米2)的上层聚酯层或下层聚酯层，并加热收缩纤维。
当以相似的方法制备两层叠层材料时，使用相应的纺丝束制备无纺织物，其中将合成纤维无纺织物叠置在预先制备的玻璃衬垫上。在优选实施方式中，合成长丝无纺织物在粘结之前收缩。针刺后，随后使用粘合剂进行支撑层/叠层材料的最终固结。
层的最终固结是通过将叠层材料涂布例如上述一种粘合剂进行的。特别是，将粘合剂涂布到叠层材料的两侧(即通过将叠层材料浸入粘合剂浴中，以使粘合剂的稳定化作用能够在外层和内层同时进行)。穿过玻璃纤维的合成长丝在玻璃纤维无纺层表面用粘合剂固定，远离其被牢固固定的合成纤维无纺层。
合成纤维可以单独收缩，因此也就是在使用这些收缩纤维制备无纺织物之前收缩。优选的是，有机纤维是当它们存在于无纺织物形式或对应的层的形式时收缩。收缩可以在机械或流体动力学预固结之前进行。任选地是，无纺层在对应的预固结之后进行收缩。收缩优选在大约140-220℃下的烘箱中进行。
为了使叠层材料达到所需的最终厚度，针刺的叠层材料/复合材料可以用市售压延机、织物/带压延机或叠层压延机进行压制。
当合成纤维无纺层通过针刺预固结时，使用10-40针/cm2。随后，将层以一部分聚酯长丝穿过复合材料/叠层材料下表面的方式针刺粘结。针刺优选为20-50针/cm2。当然，合成纤维无纺织物的预固结和叠层材料的最终固结可以在一步中进行，由此省略了单独的针刺预固结。
使用的方法是上述在线或离线方法。其中使用的针包括针尖和倒钩之间的距离大约为2-4mm的针。为了避免洞穿或简单的损伤玻璃纤维，叠层材料针刺以向前喂入比例优选小于14mm/冲程(mm/stroke)的方式进行。另一个有益效果是显著降低制备的玻璃粉尘。
玻璃纤维无纺层保持得非常完整，并且在阻燃性方面具有显著的提高。另外，由于得到的玻璃纤维无纺层的完整性，达到了高的稳定性。
本发明实施方式中使用的针以及冲程的向前喂入比例保持小的牵伸。本文中所指的牵伸发生在当针刺入无纺织物时，由此在层输送的方向移动无纺织物。在优选实施方式中的针刺机中，牵伸优选大约为0-13mm/冲程。因此，保持小的牵伸使叠层材料的机械性能和阻燃性提高。
针刺优选20-90针/cm2。如果进行了预先的针刺(例如10-40针/cm2)，最后针刺中针刺密度相应降低。因此，通过上述方法，以便捷经济的方式得到了由至少一层有机合成纤维无纺织物和至少一层无机短纤维无纺织物组成的粘结织物或叠层材料。
该叠层材料具有好的机械强度，特别是好的脱层性。因此，它们可以用作屋面毛毡、屋顶和密封膜、PVC地板材料等的支撑层。特别是，它们提高了尺寸稳定性，改进了阻燃性。
此外，上述方法制备的产品具有尺寸稳定性，实质上消除了浸渍步骤中的“颈缩”问题，显著提高了生产率。
特别是，无纺叠层材料(例如用沥青浸渍)被赋予了好的强度、有利的柔韧性和好的分层性。这些叠层材料当被用作焊接方法和铸塑方法中的屋面毛毡时，可以简单操作。另外，在屋顶上走动时不会损伤屋面毛毡。在该方法中，支撑叠层不发生香蕉弯曲，并具有非常有利的性能例如指甲撕裂强度(nail tear strength)，防撕裂传播和撕裂强度。
本发明将通过下面的实施例进行更详细的描述，其中叠层材料是在没有使用粘合剂下固结成最终状态的。
实施例1
通过在输送带上放置聚对苯二甲酸乙二酯长丝制备无规无纺织物。随后，将长丝以35针/cm2的针刺密度固结。然后将无纺层热收缩。
该无纺层的单位面积重量大约为150g/m2。将该无纺织物与玻璃短纤维无纺织物(单位面积重60g/m2)复合。所述玻璃纤维无纺织物用三聚氰胺树脂预固结，并将无纺织物放置在玻璃纤维无纺织物上。然后，以41针/cm2针刺机中以12mm/冲程的拉伸针刺粘合该无纺织物。随后，将叠层材料用苯乙烯粘合剂进行最终固结。该叠层材料在加工方向伸长35.1％处的最大拉伸负荷为563N/5cm，在横向伸长38.8％处的最大拉伸负荷为482N/5cm。
实施例2
将用三聚氰胺甲醛粘合剂预固结的玻璃短纤维无纺织物在用6个纺丝束的纺粘设备制备聚酯纤维无纺织物的过程中连续叠置。在传输方向上的无纺层上放置第一个三帘后，放上玻璃短纤维无纺织物。随后，在制成的层上再放置又一个三帘。随后在IR路线上进行处理以收缩叠层材料。随后，用10针/cm2预固结，最后进行41针/cm2的固结。随后，将叠层材料用苯乙烯粘合剂进行最终固结。
尽管本发明已经参考了其具体实施方式进行了详细描述，但是在不偏离后面权利要求范围的情况下，可以对其进行多种改变和改进以及使用等价形式，这一点对本领域技术人员来说是显而易见的。

Claims (40)

1.一种叠层材料，包含至少一层针刺复合有至少一层热收缩合成纤维无纺层的预固结无纺层，所述预固结无纺层含有玻璃短纤维，其中上层合成纤维无纺层的一部分纤维穿过玻璃纤维无纺层，非必要地穿过下层的合成纤维无纺层，并且该叠层材料含有一种固结粘合剂。
2.根据权利要求1的叠层材料，其中使用了选自脲、丙烯酸酯和三聚氰胺树脂的预固结树脂。
3.根据权利要求1的叠层材料，其中所述合成纤维无纺层的物质(克/米2)(基于重量)相同或不同。
4.根据权利要求1的叠层材料，其中合成纤维选自聚酯、聚对苯二甲酸乙二酯和聚丙烯。
5.根据权利要求1的叠层材料，其中合成纤维无纺层中的纤维是长丝。
6.根据权利要求1的叠层材料，其中合成纤维无纺层中的纤维是短纤维。
7.根据权利要求1的叠层材料，其中叠层材料包括为夹层结构的两层合成纤维长丝的无纺层和含有玻璃纤维的无纺层，其中两层长丝无纺层的物质(克/米2)比例为1∶1-1∶5。
8.根据权利要求7的叠层材料，其中所述两层合成纤维长丝的无纺层的物质(克/米2)之比为1∶1-1∶2。
9.根据权利要求1的叠层材料，其中合成纤维无纺织物是通过机械、热或流体动力学预固结的。
10.根据权利要求1的叠层材料，其中合成纤维无纺织物在针刺之前没有固结。
11.根据权利要求1的叠层材料，其中合成纤维无纺织物是热收缩的。
12.根据权利要求1的叠层材料，其中含有玻璃纤维的无纺织物中含有5-45wt％的粘合剂树脂。
13.根据权利要求1的叠层材料，其中含有玻璃纤维的无纺织物中含有10-30wt％的粘合剂树脂。
14.根据权利要求1的叠层材料，其中叠层材料在针刺机中是以小牵伸制备的。
15.根据权利要求14的叠层材料，其中针刺牵伸大约为0-13mm/冲程。
16.根据权利要求1的叠层材料，其中玻璃纤维无纺织物包括纵向排列的增强纤维或纱线，或稀松无纺布。
17.根据权利要求1的叠层材料，其中含有玻璃纤维的无纺织物包括E玻璃、C玻璃、它们的混合物或ECR玻璃的玻璃纤维。
18.根据权利要求1的叠层材料，其中所述合成纤维无纺层包括聚酯长丝无纺织物，其中一部分聚酯长丝穿过含有玻璃纤维的无纺织物，达到叠置合成纤维无纺织物层的另一侧，并且聚酯纤维长丝无纺织物是热收缩的。
19.一种制备两层或多层叠层材料的方法，其中含有玻璃短纤维的一层或多层无纺衬垫用树脂预固结，然后将该层叠置在合成纤维无纺层的下面或中间，其中合成纤维无纺层和含有玻璃纤维的预固结无纺层是通过针刺粘结在一起，结果使上面的合成纤维无纺层的一部分纤维穿过无纺层，热收缩合成纤维，并通过使用粘合剂使所述叠层材料最终固结。
20.根据权利要求19的方法，其中所述预固结树脂选自脲、丙烯酸酯和三聚氰胺树脂。
21.根据权利要求19的方法，其中所述合成纤维无纺层的厚度相同或不同。
22.根据权利要求19的方法，其中所述合成纤维层的一部分合成纤维穿过所述含有玻璃纤维的无纺衬垫。
23.根据权利要求22的方法，其中所述合成纤维层的一部分合成纤维穿过所述含有玻璃纤维的无纺层和下面的合成纤维层。
24.根据权利要求19的方法，其中无纺层中的合成纤维在与含有玻璃纤维的无纺层粘合之前收缩。
25.根据权利要求19的方法，其中所述合成纤维选自聚酯、聚对苯二甲酸乙二酯和聚丙烯。
26.根据权利要求19的方法，其中所述合成纤维无纺层中的纤维是长丝。
27.根据权利要求19的方法，其中合成无纺纤维是短纤维。
28.根据权利要求19的方法，还包括用针针刺所述玻璃短纤维无纺衬垫和合成纤维无纺层，所述针的针尖与第一倒钩之间的距离大约为2-4mm。
29.根据权利要求19的方法，其中所述针刺冲程的向前喂入比例小于14mm/冲程。
30.根据权利要求15的方法，其中所述玻璃短纤维无纺层是用纵向纤维、纱线或稀松无纺布增强的。
31.根据权利要求19的方法，其中所述合成纤维无纺织物是在140-220℃下收缩的。
32.根据权利要求15的方法，还包括一定温度下收缩所述叠层材料，所述温度至少对应于用于沥青化叠层材料的含有沥青的浴的温度。
33.根据权利要求32的方法，其中所述收缩温度为高于沥青浴温度30℃。
34.根据权利要求19的方法，其中所述玻璃纤维无纺层含有E玻璃、C玻璃、它们的混合物和ECR玻璃的纤维。
35.使用权利要求1的叠层材料作为沥青化屋面毛毡或防潮过程支撑层的用途。
36.使用权利要求1的叠层材料作为沥青瓦支撑板的用途。
37.使用权利要求1的叠层材料作为地板覆盖物的支撑层的用途。
38.根据权利要求19的用途，还包括用压延机压制叠层材料。
39.根据权利要求38的用途，其中压延机是织物/带或叠层压延机。
40.根据权利要求16的叠层材料，其中增强材料被置于叠层材料的层中或层间。
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DE19935408A DE19935408B4 (de) 1999-07-30 1999-07-30 Mehrlagenschichtstoff
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DE19950057A DE19950057B4 (de) 1999-10-16 1999-10-16 Zwei- oder Mehrlagenschichtstoffe aus Polyesterfilamentvliesen und Glasfasergeweben oder -gelegen
DE19952432.7 1999-10-30
DE19952432A DE19952432B4 (de) 1999-10-30 1999-10-30 Schichtstoff
DE19955713.6 1999-11-18
DE19955713A DE19955713C1 (de) 1999-11-18 1999-11-18 Wand- und Fußbodenbeläge
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DE19955730A DE19955730C2 (de) 1999-11-18 1999-11-18 Hydrodynamisch verbundene Trägervliese und deren Verwendung
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* Cited by examiner, † Cited by third party
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US11261602B2 (en) 2016-12-21 2022-03-01 Cretainteed Llc Fiber mat, method of making the fiber mat, and bituminous roofing product
US11332881B2 (en) 2018-01-05 2022-05-17 Certainteed Llc Fiber mat, method of making the fiber mat, and bituminous roofing product

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WO2001008882A3 (en) 2001-12-27
DK1200659T3 (da) 2007-02-26
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DK1200257T3 (da) 2003-07-14
AU7439400A (en) 2001-02-19
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DE60031546T2 (de) 2007-08-23
PT1200257E (pt) 2003-07-31
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EP1200257A2 (en) 2002-05-02
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ATE343671T1 (de) 2006-11-15
NO319186B1 (no) 2005-06-27
WO2001009428A2 (en) 2001-02-08
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CN1215219C (zh) 2005-08-17
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EP1200659A2 (en) 2002-05-02
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WO2001009428A3 (en) 2001-08-23

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