CN1367851A - 无纺层压复合材料 - Google Patents

无纺层压复合材料 Download PDF

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Publication number
CN1367851A
CN1367851A CN00811024A CN00811024A CN1367851A CN 1367851 A CN1367851 A CN 1367851A CN 00811024 A CN00811024 A CN 00811024A CN 00811024 A CN00811024 A CN 00811024A CN 1367851 A CN1367851 A CN 1367851A
Authority
CN
China
Prior art keywords
laminated material
synthetic
woven
nonwoven layers
glass fibre
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.)
Granted
Application number
CN00811024A
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English (en)
Other versions
CN1215219C (zh
Inventor
W·戈罗
M·绍普斯
J·勒纳特
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 CN1367851A publication Critical patent/CN1367851A/zh
Application granted granted Critical
Publication of CN1215219C publication Critical patent/CN1215219C/zh
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • 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
    • 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
    • B32B5/22—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
    • 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
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    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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    • D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • 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
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0013—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using multilayer webs
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • 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
    • D06N5/00—Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • 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
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    • B32B2307/732—Dimensional properties
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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
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Abstract

本发明提供一种不使用粘合剂进行最终固结的层压材料及其生产方法。该层压材料包括至少一层含有用树脂预固结的玻璃短纤维的无纺毡片、和至少一层合成纤维的无纺层。合成无纺层和玻璃纤维的预固结的无纺毡片通过针刺结合在一起,使得上层合成无纺层的一部分纤维可以经由下层合成无纺层穿过玻璃纤维的无纺毡片。合成纤维经过热收缩,且该层压材料不使用粘合剂。

Description

无纺层压复合材料
                   发明背景
发明领域
本发明涉及一种生产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的无纺层制成的多层层压材料的方法，产品及其用途。
相关技术的描述
含有结合的织物的层压材料用于结构例如住宅和工业建筑结构的墙壁和地板覆盖物。它们特别用于屋顶油毡和绝缘，其中层压材料用作载体材料。结合的纤维特别用作沥青屋顶油毡和膜中的载体。当然，这些层压材料可以被其它材料例如聚氯乙烯涂覆。
由至少无纺合成纤维和无纺矿物纤维生产各种层压材料的方法是工业公知的。例如EP 0 176 847 A2公开了一种由无纺人造纤维、特别是聚酯单丝与一种矿物纤维无纺层组成的层压材料。人造纤维的无纺织物和矿物纤维的无纺织物经过预固结，然后通过针刺结合在一起。
欧洲专利文件EP 0 242 524 B1建议沿着纵向方向加入增强纱，其中无纺材料由矿物纤维制成。其中的实施例B公开了将复合材料进行最终固结，通过加入本领域公知的粘合剂来完成。
欧洲专利文件EP 0 379 100 B1公开了一种由单丝无纺织物和玻璃纤维无纺织物制成的层压材料，其中该层压材料如下制成，先将玻璃纤维无纺织物进行预固结，然后用合成纤维无纺织物针刺该无纺织物，最后用不含蜜胺甲醛预缩聚物的聚合物水溶液来完成最后的固结(consolidation)，所述预缩聚物具有蜜胺/甲醛摩尔比为1∶1.0至1∶3.5，其中已将约0.5-5重量％的常用硬化剂加入该溶液中。
相似的双层层压材料描述于南非文件ZA 94/02763 A中。此外，该南非文件公开了三层层压材料，其中玻璃短纤维的无纺织物置于两个通过针刺预先稳定的聚酯单丝无纺织物上，此时通过进一步的针刺过程将三层结合在一起。聚酯无纺织物的单丝被拉伸穿过玻璃短纤维的无纺织物。
DE 195 21 838 A1描述了一种紧密结合的织物，其由至少三层组成，中间层是有机纤维织物，在其两侧上都有增强层。优选，两个增强层由无机纤维制成。该文献还建议通过针刺和/或通过用热或化学粘合剂粘合来增强结合的织物。
EP 0 603 633 B1描述了一种阻燃性层压材料，包括至少一层固结的纺丝铺置的无纺织物，玻璃纤维的纱布(scrim)层和金属箔。所述层压材料可以相似地包括玻璃纤维纱布，其夹在两层聚酯单丝无纺层之间，并另外包括上述金属箔。纱布层的玻璃纤维是玻璃丝，也就是指玻璃的多根丝。玻璃丝可以显示是合股的，但是它们可以非合股的单丝束存在。这些层可以通过机械方式(例如针刺)或通过化学粘合剂(例如聚乙烯醇或丁二烯-苯乙烯共聚物)固结。可以相似地使用热塑性粘合剂，特别是纤维的形式。
另一种多层层压材料描述于欧洲专利EP 0 187 824 B1，其中包括由铺置的有机纤维得到的织物纤维层。该层压材料用基于氟聚合物分散体的粘合剂处理。
欧洲专利EP 0 403 403公开了多层结构，其中除了玻璃纤维无纺织物之外还使用聚酯短纤维的无纺织物。其中的玻璃短纤维需要具有与表面平行的严格定向。
欧洲专利EP 0 572 891 A1公开了无纺织物和纱布的层压材料，其中除了金属箔之外，显示与EP 0 603 633 B1所述相似的结构。这些层压材料相似地用粘合剂处理。
欧洲专利EP 0 806 509描述了一种载体层，其含有织物和增强材料，其中增强材料用于中和外力，特别是当伸长率为0-1％时。其中也建议使用粘合剂。
与上述层压材料相关的一些缺点在于它们要求在粘合剂的协助下最终固结。最终固结的目的是提高用作屋顶油毡和绝缘带的层压材料以及经过沥青处理的产品的强度。
与商业可得的层压材料相关的另一个缺点是缺乏机械强度(例如抗分层)、尺寸稳定性、撕裂传播和阻燃性能。
为了满足屋顶、密封、地板和绝缘用途的要求和克服现有技术的不足，本发明的目的是提供一种由至少一层有机合成纤维的无纺层和至少一层无机短纤维的无纺层制成的结合织物或层压材料，其通过快速便捷的方式制得。
本发明的另一个目的是提供不用粘合剂进行最终固结的层压材料，和提供改进的机械强度，包括在用沥青或其它合成材料饱和、浸渍或层压时的撕裂传播强度、剥离强度和指甲撕裂强度。
本发明的另一个目的是使用层压材料作为载体网，特别是沥青网。
本发明的另一个目的是这样的层压材料，其可以容易地用沥青或其它合成材料饱和和浸渍，从而用作用于屋顶油毡、密封膜、地板覆盖物等的载体层。
本发明的另一个目的是提供一种生产具有改进的挠性、在沥青处理期间和之后的尺寸稳定性、和特别是阻燃性能的层压材料的方法。
本发明的另一个目的是提供层压材料，当其用作沥青网或膜时，合成无纺织物的比例与玻璃纤维无纺织物的比例可以降低，且不会出现显著的对结合织物的不利影响，并具有改进的阻燃性能、有利的挠性和良好的抗分层性能。另外，所制得的沥青网可以容易地用作在焊接和浇铸过程中的屋顶油毡。这些网由于是热收缩过的，所以不具有香蕉状(banana)弯曲效应。
本发明的其它目的和方面将通过以下说明书和权利要求表现出来。
发明概述
根据本发明的层压材料和其生产方法，已确定可以生产两层或多层的层压材料，其中该层压材料不使用粘合剂进行最终固结。
根据本发明的第一个方面，提供一种不使用粘合剂进行最终固结的层压材料。该层压材料包括至少一层含有用树脂预固结的玻璃短纤维的无纺毡片、和至少一层合成纤维的无纺层。合成纤维的无纺层和含有玻璃纤维的预固结的无纺毡片通过针刺结合在一起，使得上层合成无纺层的一部分纤维可以经由下层合成无纺层穿过含有玻璃纤维的无纺毡片。合成纤维已经过热收缩，且该层压材料不使用粘合剂进行最终的固结。
根据本发明的另一方面，提供一种生产两层或多层层压材料的方法。一层或多层含有玻璃短纤维的无纺毡片用树脂预固结，然后置于合成纤维的无纺层之下或之间，其中合成纤维的无纺层和玻璃纤维的预固结无纺毡片通过针刺结合在一起，使得上层合成无纺层的一部分纤维可以穿过无纺毡片。合成纤维已经过热收缩，且该层压材料的形成不需使用粘合剂进行最终的固结。
本发明的优选实施方案的描述
现在将参考示例的实施方案说明本发明。在本发明的第一方面，至少一层含有玻璃短纤维的无纺毡片与作为其它层的至少一层合成纤维的无纺层结合在一起。在此处，毡片定义为含有短纤维(例如玻璃或合成纤维)或一层或多层单丝纤维。两层或多层通过针刺结合在一起，使得合成无纺层的一部分纤维穿过玻璃纤维的无纺织物。两层或多层通过这样的方式针刺结合在一起，其中合成纤维可以延伸穿过整个玻璃纤维的无纺毡片。
合成材料的无纺织物可以是短纤维，但优选单丝纤维。这些单丝纤维也被本领域技术人员称为“未切断的”纤维或连续纤维。短纤维或单丝可以作为多组分纤维存在，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聚合物或共聚物，例如聚酯、聚丙烯、聚对苯二甲酸乙二酯、聚酰胺或聚烯烃。优选使用聚丙烯，更优选使用聚对苯二甲酸乙二酯。在一个示例的实施方案中，合成的无纺织物可以通过机械、流体力学、热的方式或通过在合成纤维将会完全收缩的温度下预固结。另外，合成无纺织物可以在与玻璃纤维无纺层结合之前、在预固结之前或之后收缩，但优选在与玻璃纤维无纺织物结合之前收缩。
当然，层压材料可以包括合成纤维的第三层，其夹在无纺玻璃纤维毡片之间。当存在例如聚酯的两层或多层无纺合成材料、特别是两层单丝无纺层时，优选无纺织物的gsm物质的比率(即重量/面积，优选以克/米2为单位)在约1∶1至1∶5的范围内。优选，这些无纺织物的gsm物质的比率在约1∶1至1∶2的范围内，优选无纺织物在针刺之前不进行固结。
在优选的实施方案中，预制的玻璃无纺毡片在通过针刺与合成无纺织物结合之前用粘合剂预固结。玻璃纤维的直径是约8-16微米，优选约10-13微米。纤维的长度是约8-32微米，优选8-18微米。合适的粘合剂包括例如脲-甲醛、蜜胺-甲醛、酚醛、环氧、乙酸乙烯酯、聚氯乙烯、乙烯醇、丙烯酸酯和其它热塑性和热固性树脂。粘合剂的用量占无纺玻璃纤维的约5-45重量％，优选10-30重量％。
玻璃无纺织物可以使用干法来生产，但优选使用湿法生产。因此，玻璃纤维毡片的gsm物质为约30-150克/米2。甚至更优选gsm物质为约50-90克/米2。
玻璃纤维的无纺层可以包括增强材料，其为短纤纱、多丝纱、单丝或玻璃丝或其它合成材料的形式，例如位于纵向方向的高韧性聚对苯二甲酸乙二酯、芳族聚酰胺、聚酯，和其它纱布形式的增强材料。此处所述的“纱布”是指单丝的铺展层，以及织造丝。增强丝、纱或纱布还可以处于相对于纵向或横向方向的任何角度，例如10-30度。另外，增强材料可以置于其它层之间或之中。增强材料的间隔是约1-35毫米。丝的滴定度是约200-1500分特(dtex)，优选约300-700分特。本领域技术人员将能认识到分特或特(tex)分别是相当于克/10000米或克/1000米的单位。
所述层压材料可以通过在线或非在线方法生产。根据本发明的另一个示例的实施方案，在非在线方法中生产双层层压材料。该层压材料包括预固结的聚酯单丝无纺织物和预固结的玻璃短纤维无纺织物。聚酯无纺织物通过针刺而预固结。
有机合成无纺织物优选由聚酯纤维通过DE OS 24 60 755所述的纺丝粘合法而制成，将其引入本文作参考。优选，所用的合成材料是聚对苯二甲酸乙二酯或共聚酯。然后通过针刺进行预固结，其中排列10-40针/厘米2。预固结的单丝无纺织物显示gsm物质(gsmsubstance)为约60-250克/米2，优选100-230克/米2。纤维的收缩可以在预固结之前或任选地在预固结之后进行。在140-220℃温度下加热，或在对应于用于用沥青浸渍该层压材料的含沥青的浴的温度下加热。本发明人也考虑使用其它预固结方法，例如机械、流体力学或加热(例如压延机)方法，且包括在本发明的范围内。
玻璃纤维的无纺织物根据所谓的湿法生产，其中E或C级纤维、其混合物和其它商业可得的玻璃例如ECR玻璃用上述脲、蜜胺和其它粘合剂树脂预固结。本领域技术人员将知道最多40％的玻璃纤维可以被其它纤维代替。具体地说，基于纤维素的纤维、聚丙烯腈、聚酯、聚酰胺等。
进行湿法固定，涂布约5-45％、优选约10-30％的涂料。因此，gsm物质为约30-120克/米2，优选约50-90克/米2。另外，增强添加剂和纱例如参考上述实施方案所述的那些可以加入无纺玻璃纤维层中。预固结的玻璃无纺织物特别是有利的，如在纵向上测得的应力一应变曲线所证实，其中样品的宽度是5厘米，所施加的应力至少是100N，伸长率小于3％，优选小于2.5％。
预制的两层无纺层层叠并通过针刺结合在一起。例如先针刺聚酯单丝，以便至少一部分单丝穿过玻璃纤维无纺织物到达背对合成无纺织物的那一侧，并可能缠合在那里。
在另一个优选的实施方案中，生产三层或多层层压材料。例如，玻璃纤维层位于聚酯外层之上，然后在其上涂布第二层聚酯层，得到具有至少一层聚酯外层的层压材料。
非在线方法的特征在于合成材料无纺织物和玻璃纤维无纺织物分别生产。合成纤维经过热处理，例如通过将无纺织物置于温度为约140-220℃的烘箱或红外场中，使得随后的处理将不会导致纤维和/或无纺织物的收缩。所得的无纺织物然后与玻璃纤维无纺织物通过针刺结合。因此，无论采用何种方法，不需要使用用于固结各层的粘合剂。
在在线方法中，在无纺合成层的生产中将玻璃纤维无纺织物引入层压材料中。特别是，一个或几个聚酯单丝幕(curtain)先沉积在移动的传送带上。玻璃纤维无纺织物铺展在一层或多层聚酯上，在其上任选地沉积额外的聚酯层。聚酯的无纺层在不同层的结合之前或任选之后经过热收缩。
根据一个优选实施方案，通过所谓的在线方法将玻璃纤维无纺织物引入合成聚酯无纺层的纺粘物之间。对应于所生产的纤维幕的纺丝束(即合成无纺织物)进行纺丝或拉伸通过位于移动位置的通道，例如传送机。此时，预固结的无纺玻璃短纤维层铺展在预固结的或非固结的无纺聚酯单丝层上，或相反。根据需要加入额外层。在优选的实施方案中，生产具有相同或不同gsm物质的聚酯上层和下层，并施加热能以使纤维收缩。
以相似的方式，当生产双层层压材料时，相应的纺丝束用于生产无纺织物，其中合成无纺织物沉积在预制的玻璃毡片上。在优选的实施方案中，合成单丝无纺织物在结合之前收缩。
合成纤维可以分别收缩，所以在使用这些收缩的纤维生产无纺织物之前，优选有机纤维当以无纺织物或以相应层的形式存在时是已收缩的。收缩可以在机械或流体力学预固结之前进行。任选地，无纺织物在相应的预固结之后收缩。收缩优选通过在烘箱中于约140-220℃温度下加热来进行。
为了获得层压材料的所需最终厚度，针刺的层压材料/复合材料可以通过用商业可得的压延机、织物/带式压延机或层压压延机进行处理来压制。
在通过针刺使合成无纺织物预固结的情况下，排列10-40针/厘米2。随后，通过针刺以这样的方式结合各层，使得一部分聚酯丝穿过层压材料/复合材料的下表面。针刺优选安排20-50针/厘米2。当然，合成无纺织物的预固结和层压材料的最终固结可以在一步中进行，从而不需要通过针刺独立地进行预固结。
所用的方法是上述在线或非在线方法。所用的针包括针点和倒钩之间的距离为约2-4毫米。为了避免破裂或简单地损害玻璃纤维，层压材料的针刺在前进进料率(forward feed ratio)优选小于14毫米/刺程(stroke)下进行。另外的益处是显著降低所产生的玻璃尘。
玻璃纤维无纺层大部分保持原样，并在其阻燃性能方面表现出显著的改进。另外，因为所得玻璃无纺织物的完整性，可以达到高的稳定性。
本实施方案所用的针以及每刺程的前进进料率保持较小的牵引(draft)。此处所述的“牵引”是当针刺入无纺织物时发生，从而使无纺织物在层的输送方向上移动。优选实施方案的针刺机的牵引优选是约0-13毫米/每刺程。因此，保留小的牵引使层压材料具有改进的机械性能和阻燃性能。
针刺优选在20-90针/厘米2下进行。如果预先已进行了针刺(例如10-40针/厘米2)，则在最终针刺过程中的针密度相应地减少。所以，通过上述方法，以便捷经济的方式提供了由至少一层非有机合成纤维无纺织物和无机短纤维无纺织物制成的结合织物或层压材料。该层压材料显示良好的机械强度和特别是良好的抗分层质量。所得的层压材料能容易地用沥青或其它合成材料例如PVC和改性聚烯烃饱和和浸渍或层压。因此，该层压材料可以用作屋顶油毡、屋顶和密封膜、PVC地板覆盖物等的载体层。特别是，该层压材料显示改进的尺寸稳定性和特殊的阻燃性能，且在最终固结中不需要使用粘合剂，在沥青处理期间或之后还保持其尺寸，所以实质上消除了在浸渍步骤中导致较高生产速率的“缩颈”问题。
具体地说，无纺层压材料(例如用沥青浸渍)具有突出的强度，有利的挠性和良好的抗分层性能。这些层压材料当在焊接和铸塑期间用作屋顶油毡时易于加工。另外，可以在屋顶上走过，而不会损伤油毡。以这种方式，载体层压材料不会发生香蕉状弯曲，且具有很有利的性能，例如指甲撕裂强度、抗撕裂传播性和改进的剥离强度。
本发明将通过以下实施例进一步说明，其中层压材料最终固结时不需要粘合剂。
实施例1
无纺毡片如下生产：将聚对苯二甲酸乙二酯单丝沉积在表面或传送机上，在烘箱中使无纺织物热收缩，然后在33针/厘米2下通过针刺使其预固结。无纺织物的基本重量是约180克/米2。
无纺织物与用蜜胺树脂预固结的玻璃短纤维无纺织物(60gscm)结合，其中无纺玻璃纤维置于无纺聚酯之上。两种无纺织物通过针刺互相连接在一起，在其上安排41针/厘米2，前进进料率是12毫米/刺程。然后，无纺织物在通过200℃的烘箱过程中进行收缩。
在伸长率≤3％下，宽度为5厘米的层压材料样品显示拉伸强度为148N。在伸长率为53％下，宽度为5厘米的样品最终的纵向强度是410N，在伸长率为56％下，宽度为5厘米的样品的横向强度是382N。
在沥青处理之后，宽度为5厘米的样品的纵向和横向强度分别是900N和731N。
惊奇的是，已发现在伸长率≤3％下，对于宽度为5厘米的层压材料样品，玻璃无纺织物的强度为148N，使得可以对屋顶油毡进行优异的加工。另外，发现所用的聚合物改性的沥青能提高屋顶油毡的强度，且不会降低伸长率。所得的屋顶油毡显示优异的阻燃性能。
实施例2
在在线方法中，聚酯单丝无纺织物从6个纺丝束的装置纺丝粘合制得。在开始三个帘幕沉积后，各层进行热收缩，并使被脲预固结的且具有与实施例1相同gsm物质的玻璃短纤维无纺织物连续地按照输送方向引入。然后，再沉积三个帘幕，并进行热收缩。然后在10针/厘米2下进行预固结，然后用32针/厘米2进行随后的固结。然后，层压材料在200℃的烘箱中进行热处理。实施例3
在下表中，本发明产品的质量(即沥青屋顶油毡的最大屈服载荷)与用粘合剂通过载体网的沥青处理得到的屋顶油毡进行比较。
其中，根据本发明的层压材料在不使用用于最终固结的粘合剂下制得，然后引导经过沥青浴。相同的在线方法用在沥青处理之前已被粘合剂固结的层压材料进行。经过粘合剂最终固结的层压材料是两层载体，具有根据本发明制得的170克/sqm聚酯无纺织物和60克/sqm玻璃无纺织物。不使用粘合剂固结得到的层压材料是两层载体，具有根据本发明制得的180克/sqm聚酯无纺织物和60克/sqm玻璃无纺织物。
             表
      沥青处理后的最大屈服载
                      荷
不使用粘合剂的载体    MD 843N/5cm
                      CD 646N/5cm
使用粘合剂的载体      MD 718N/5cm
                      CD 532N/5cm
MD：机器方向          CD：横向
数据的比较显示沥青屋顶油毡的强度高于通过粘合剂另外固结的沥青层压材料得到的沥青屋顶油毡的强度。
在铺在屋顶上之后，根据本发明获得的屋顶油毡显示改进的抗起泡和抗分层的性能。这是因为本发明的产品被沥青更好地浸渍。
为了检验起泡效果，沥青化样品进行以下处理。切下具有相同面积(厘米2)的样品表面，并在60℃下在水中浸渍14小时。然后，样品在110℃下干燥30分钟，观察起泡现象。证明与在沥青处理之前已被最终稳定的产品相比，本发明的产品的起泡显著减少。
虽然本发明已参考具体实施方案进行了描述，但是本领域技术人员显然明白可以进行各种改变和改进，使用等价方式，只要不偏离由权利要求的保护范围即可。

Claims (41)

1.一种不使用粘合剂进行最终固结的层压材料，包括：至少一层含有用树脂预固结的玻璃短纤维的无纺毡片、和至少一层合成纤维的无纺层，其中合成无纺层和含有玻璃纤维的预固结的无纺毡片通过针刺结合在一起，使得上层合成无纺层的一部分纤维经由下层合成无纺层穿过含有玻璃纤维的无纺层，和其中合成纤维已经过热收缩，且该层压材料不使用粘合剂进行最终固结。
2.根据权利要求1的层压材料，其中所述预固结树脂选自脲、丙烯酸酯、蜜胺、酚醛、环氧、乙酸乙烯酯、聚乙烯醇、聚氯乙烯树脂。
3.根据权利要求1的层压材料，其中所述合成无纺层的gsm物质(基本重量)是相同或不同的。
4.根据权利要求1的层压材料，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。
5.根据权利要求1的层压材料，其中所述合成无纺纤维是单丝状的。
6.根据权利要求1的层压材料，其中所述合成无纺纤维是短纤维。
7.根据权利要求1的层压材料，其中所述层压材料包括两层单丝合成无纺层和处于夹层结构的含有玻璃纤维的无纺织物，其中两层单丝合成无纺织物的gsm物质的比率是1∶1至1∶5。
8.根据权利要求7的层压材料，其中所述两层单丝无纺织物的gsm物质的比率是约1∶1至1∶2。
9.根据权利要求1的层压材料，其中所述合成无纺织物通过机械、热或流体力学方式预固结。
10.根据权利要求1的层压材料，其中所述合成无纺织物在针刺之前不固结。
11.根据权利要求1的层压材料，其中所述合成无纺织物经过热收缩。
12.根据权利要求1的层压材料，其中所述玻璃纤维的无纺织物含有5-45重量％的粘合剂树脂。
13.根据权利要求1的层压材料，其中所述玻璃纤维的无纺织物含有10-30重量％的粘合剂树脂。
14.根据权利要求1的层压材料，其中所述层压材料在针刺机中以较小的牵引来生产。
15.根据权利要求14的层压材料，其中所述针刺的牵引是约0-13毫米/刺程。
16.根据权利要求1的层压材料，其中所述层压材料包括增强材料。
17.根据权利要求1的层压材料，其中所述含玻璃纤维的无纺织物含有E级、C级玻璃纤维、其混合物和ECR玻璃。
18.根据权利要求1的层压材料，其中所述合成无纺层包括聚酯单丝无纺织物，和其中一部分聚酯单丝穿过含玻璃纤维的无纺织物，并到达另一侧，在其上沉积合成无纺层，和聚酯单丝无纺织物经过热收缩。
19.一种生产两层或多层层压材料的方法，其中一层或多层含有玻璃短纤维的无纺毡片用树脂预固结，然后将所述层沉积在合成纤维的无纺层之下或之间，其中合成纤维的无纺层和含有玻璃纤维的预固结的无纺毡片通过针刺结合在一起，使得上层合成无纺层的一部分纤维穿过无纺毡片，使合成纤维热收缩，和形成所述层压材料，且不使用粘合剂进行最终的固结。
20.根据权利要求19的方法，其中所述预固结树脂选自脲、丙烯酸酯和蜜胺、酚醛、环氧、乙酸乙烯酯、聚乙烯醇、聚氯乙烯树脂。
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是相同或不同的。
22.根据权利要求19的方法，其中所述合成层的一部分合成纤维穿过所述玻璃纤维的无纺毡片。
23.根据权利要求22的方法，其中所述合成层的一部分合成纤维穿过所述含玻璃纤维的无纺层和下面的合成层。
24.根据权利要求19的方法，其中在无纺层中的合成纤维在与含玻璃纤维的无纺层结合之前经过收缩。
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，其中所述合成无纺纤维是单丝状的。
27.根据权利要求19的方法，其中所述合成无纺纤维是短纤维。
28.根据权利要求19的方法，进一步包括用针将所述含有玻璃短纤维的无纺毡片与合成纤维的无纺层针刺在一起，针点和第一倒钩之间的距离是约2-4毫米。
29.根据权利要求19的方法，其中所述针刺在小于14毫米/刺程的前进进料率下进行。
30.根据权利要求19的方法，其中所述玻璃短纤维的无纺毡片用纵向纤维、纱或纱布增强。
31.根据权利要求19的方法，其中所述合成无纺织物在140-220℃温度下收缩。
32.根据权利要求19的方法，进一步包括用压延机压制所述层压材料。
33.根据权利要求32的方法，其中所述压延机是织物/带式或层压压延机。
34.根据权利要求19的方法，进一步包括使所述层压材料在至少对应于用于沥青化该层压材料的含有沥青的浴的温度下收缩。
35.根据权利要求34的方法，其中所述收缩温度比沥青浴的温度最多高30℃。
36.根据权利要求19的方法，其中所述含玻璃纤维的无纺层包括E或C级纤维、其混合物和ECR玻璃。
37.使用权利要求1的层压材料作为沥青屋顶油毡或防潮过程的载体的方法。
38.使用权利要求1的层压材料作为沥青木瓦的载体的方法。
39.使用权利要求1的层压材料作为地板覆盖物的载体的方法。
40.根据权利要求16的层压材料，其中所述增强材料是纤维、沿着纵向前进的纱或纱布。
41.根据权利要求40的层压材料，其中所述增强材料处于所述层压材料的层之内或之间。
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CN111020884A (zh) * 2011-09-30 2020-04-17 欧文斯科宁知识产权资产有限公司 形成玻璃纤维的分层叠毡的连续方法及其模塑叠毡
CN103216047A (zh) * 2012-01-20 2013-07-24 永得宁集团 耐火性纤维素-沥青屋顶覆盖片材及其制造方法
CN102765230A (zh) * 2012-07-27 2012-11-07 深圳市科聚新材料有限公司 复合纤维布、其应用和应用方法
CN102765230B (zh) * 2012-07-27 2015-02-04 深圳市科聚新材料有限公司 复合纤维布、其应用和应用方法
CN102991027A (zh) * 2012-09-30 2013-03-27 浙江联洋复合材料有限公司 汽车顶棚用针刺复合环保毡及其生产方法
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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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CN110029450A (zh) * 2019-04-27 2019-07-19 江阴市华思诚无纺布有限公司 一种高延伸油毡基布的生产方法

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WO2001008879A3 (en) 2001-08-23
NO326751B1 (no) 2009-02-09
WO2001009420A2 (en) 2001-02-08
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US7199065B1 (en) 2007-04-03
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EP1200659B1 (en) 2006-10-25
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DE60031546D1 (de) 2006-12-07
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CN1646762A (zh) 2005-07-27
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