DE60025835T2 - COMPOSITE MATERIALS COMPRISING TWO OR MORE LAYERS OF PLASTIC FILAMENTARY CARBIDE LAYER AND GLASS TISSUE CARRIAGE AND GLASS NETWORKS - Google Patents

Abstract

A laminate of two or more layers comprising an organic synthetic filament (polyester) non-woven layer and a woven web or scrim of glass fiber, pre- consolidated with a binding agent. The non-woven layer is bonded to the woven layer by needling so that part of the polyester filament penetrate through the laminate an emerge at the lower surface and lie adjacent to it. The formed laminate is consolidated with an acrylate or styrene binder An Independent claim is included for the method of producing the laminate which may have two layers or be a sandwich of the woven web between non-woven layers

Description

Background of the invention

1. Field of the invention

The The invention relates to a method for producing a laminate with two or more layers, based on at least one organic synthetic Filament fleece and glass fiber fabric or -gelege, and a product and a use for this.

2. Description of the state of the technique

laminates, made of non-woven fabrics are suitable for wall and floor coverings of Constructions such as e.g. Residential and commercial buildings. They are special suitable for Roofing boards and insulation, the laminates being a carrier material be used. The nonwoven fabrics find particular applicability as a carrier in bitumen roofing membranes and membranes. Of course, these laminates can work with others Materials such as e.g. Polyvinyl chloride, coated.

Various Laminates based on polyester filament nonwovens and fibers, which are made of glass fibers are made in the Industry known. For example, the South African patent document discloses ZA 94/02763 Laminates with two or more layers, including one Fabric of glass staple fibers and a nonwoven continuous Filaments that are pre-consolidated by needling.

The German patent document DE 195 21 838 A1 relates to a compact composite fabric having at least three layers and wherein the middle layer is a woven fabric of inorganic fibers.

The German patent document DE 195 43 991 A1 discloses a fabric used as reinforcing structures in road construction. The nonwoven fabric is a net that is bonded to a nonwoven.

At long last describes the European Patent document 0 806 509 A1 discloses a carrier with a textile fabric, which may be a nonwoven polyester, and a reinforcement, wherein the reinforcement a Garngelege, a fabric, a fleece, etc. may include.

Some the disadvantages associated with the laminated composites described above related, are the mechanical, dimensional and fire retardant properties of these composites when used in bitumen roofing membranes become.

Around to meet the requirements of the roofing industry, as well as the welding, Soil and insulation industries, it is an object of the invention to a laminate available which has two or more layers, including synthetic ones Nonwoven fabrics and woven fabrics or made of glass fibers by Needled and joined together by a binder.

A Another object of the present invention is to provide a laminate for disposal to ask, during which the minimized when producing glass fragments, wherein the formed dust is reduced.

A another object of the invention is, laminates available to provide that have two or more layers and improved mechanical and dimensional stability exhibit.

Yet another object of the invention is a laminate available which can be used in bitumen roofing fabrics, which have improved delamination and fire resistant properties.

Other Objects and aspects of the invention will become apparent to those skilled in the art Review of the description and the attached claims obviously.

Summary the invention

In accordance In a first aspect of the invention, a laminate is formed two or more layers as defined in claim 1 are provided.

The Laminate includes at least one organic synthetic filament nonwoven layer and at least one fabric or scrim of glass fibers, preconsolidated through a binder. The organic synthetic fleeces and the fabric or scrim is so connected by needling a part of the polyester filaments preferably penetrates through the laminate and at the bottom surface of the laminate appears and rests there. The formed laminate becomes a final consolidation by an acrylate or a styrene binder subjected.

In accordance with a second aspect of the invention, there is provided a method of making laminates having two or more layers as defined in claim 16. The method involves providing a web or web of glass fibers, wherein the web or scrim is preconsolidated by a binder. The organic synthetic filament web is placed on the pre-consolidated fabric or scrim. Optionally, the fleece is placed on either side of the fabric or scrim, where it forms a sandwich arrangement. The fabric and nonwoven are joined together by needling such that a portion of the organic synthetic filaments penetrate through the laminate and appear and abut the lower surface of the laminate. The resulting laminate is treated with an acrylate or styrene binder to solidify it.

Detailed description of the preferred embodiments the invention

The Invention will now be described with reference to exemplary embodiments thereof described. In an exemplary embodiment of the invention synthetic nonwovens and preconsolidated fabrics or glass scrims connected together to form a laminate. The tissues or scrim and the fleece are made by needling in a manner with each other connected to that part of the synthetic filaments through the complete Tissue layer extends therethrough. The synthetic fibers become preferably shrunk by applying heat before needling.

The synthetic nonwoven material may be staple fiber, but is preferred Filament fibers. These filament fibers are also known to those skilled in the art as "endless" fibers. The fibers are preferably organic synthetic fibers, such as e.g. Polypropylene, polyester, polyamide and other commonly used artificially produced organic fibers.

The Synthetic nonwoven material can be calendered or needled be pre-consolidated. The fabric mat may also be preconsolidated by a binder become. Suitable binders include polyvinyl acetate, pure Acrylate and other hydrophobic substances or binders that are hydrophobic Contain funds.

Needling is listed to join the layers, placing the stitches at a density of, for example, 30 to 50 stitches / cm ² . The laminate undergoes final consolidation with a binder selected from the group consisting of pure acrylate, copolymers of styrene, butadiene and acrylates. These binders provided can be mixed with thermosetting binders such as urea or melamine resins. Preferably, the laminate is consolidated by a coating of 5 to 35% by weight and preferably 14 to 18% by weight of an acrylate or styrenic binder.

In particular, the process can be carried out by forming a nonwoven fabric of continuous fibers or filaments by a spin-nonwoven process as described in DE-OS 24 60 755 and incorporated herein by reference in its entirety. Preferably, the fibers are selected from the group consisting of polyethylene terephthalate, copolyester, and preferably polyester. Thereafter, the fibers are preconsolidated by hot calendering whereby the web is thermally preconsolidated. Alternatively, pre-consolidation is performed by needling, placing about 20 to 40 stitches per cm ² . The preconsolidated filament web has a basis weight of about 50 to 350 g / m ² and preferably about 100 to 230 g / m ² .

The Woven fabric or scrim fabric is made e.g. by Using continuous glass fibers in a chain direction (i.e. Longitudinal direction) and glass staple fiber in the weft direction (i.e., transverse direction). Glass filaments are as warp yarns, whereas staple fiber yarns or staple fiber tapes are preferred Weft yarns are preferred. The glass staple fibers are preferably a titer of 330 tex to 660 tex. It is by the expert easily recognized that dtex or tex is a unit that is g / 10,000 m or g / 1 000 m.

Of course they can Chain yarns are made from staple fibers or from slivers and Glass filaments can used as weft yarns. A dense nonwoven fabric is particularly advantageous Consequently, the warp and weft yarns are selected accordingly. It is advantageous to select weft and warp yarns, in which the titer differs by at least a factor of 2. In the exemplary execution the warp density is preferably about 1 to 8 yarns per cm. The fabric is further characterized by a binder selected from the group consisting of polyvinyl acetate, starch, urea or melamine resin, presolidified.

The polyester fleece is then applied to the fabric produced, where both are needled together placing eg 30 to 50 stitches per cm ² . The polyester filaments are conveyed with a forward draw ratio of less than 14 mm / stitch to allow at least a portion of the filaments of the glass fiber fabric to penetrate to the side facing away from the synthetic web to which the filaments abut. In addition, performing the needling with the above feeding ratio reduces the destruction of the laminate, and particularly the glass fibers.

The bonded laminate is subjected to final consolidation by applying an acrylate or styrenic binder. Preferably, the binder is used in an amount of 5 to 35% by weight, preferably 14 to 18% by weight. It can easily be understood that said weight is the weight of the glass fiber fabric and the polyester fiber lament mats.

Even though a final consolidation using the above binder used Nonetheless, it is nevertheless possible to laminate the laminate solidify reduced amount of binder. Thus, a lot of 10%, preferably 7.5% and preferably 5% or less.

The synthetic fibers can thermally treated between a temperature of about 140 to 220 ° C. become. As a result, subsequent treatment of the laminate produces no additional shrinkage the filaments of the fleece.

The synthetic fibers can be shrunk separately and thus, before using a fleece this shrunken fibers is produced. Preferably The organic synthetic fibers shrunk when in the mold a nonwoven or in the form of corresponding layers are. Shrinkage may be in front of a mechanical or hydro-dynamic Pre-consolidation take place. Optionally, the fleece after a corresponding pre-consolidation shrunk. The shrinking is preferably carried out by heating in an oven at a temperature of about 140 to 220 ° C.

In addition, can Shrinking performed Be after the carrier fleece was tied. The carrier However, before bituminizing or coating with materials, such as. shrunk bitumen-like materials, PVC, etc. Thus, the carrier becomes through a hot one liquid Bitumen bath piped to make a roofing felt. As a result, the mechanical properties and in particular the delamination properties of the Laminate, which is obtained by this method, improved. Furthermore, the fire resistance properties become as a result of the relatively intact layers improved.

The in accordance The two-layer laminate produced by the invention reduces the Amount of glass fragments and dust generated, causing an injury of the worker avoids damage to the environment. Furthermore provides a lower amount of glass dust produced process advantages while the final consolidation stage available.

In accordance In another exemplary embodiment, a laminate is used made with three layers (i.e., sandwich structure). Especially a polyester filament nonwoven forms the upper and lower layers, while the glass fiber fabric or scrim is the middle layer. The glass fabric or -gelege is manufactured using continuous Chain-direction glass fibers and glass staple fibers in the weft direction.

The Glass cloth is made by a binder before binding the synthetic Fleece preconsolidated by needling. The glass fibers can be selected from E, C, mixtures thereof, ECR glass and suitable binders for the treatment of the woven glass include polyvinyl acetate and Strength, Urea or melamine resin. The synthetic filament fleece is placed on the pre-consolidated fabric, the layers through Needling be connected. Optionally, the polyester fleeces pre-consolidated by needling. Filaments from the first fleece penetrate through the glass fiber fabric and through the optional second Polyester fleece, which is on the opposite side of the glass fiber fabric appropriate and provides the effective anchorage. In accordance with this embodiment the needles used have a space between the needle tip and barbs of about 2 to 4 mm.

The Laminates are made by the method outlined above referring to the two-layer laminate. To a tearing or a easy destruction To avoid the glass fibers, the needling with a forward thrust ratio of less than 14 mm / stitch executed. The needles associated with the forward thrust ratio of the Stitches maintain a small delay. One Warpage, as defined herein, occurs when a needle is inserted into the Fleece punctures, with the fleece in the direction of the further transported Layers moved. The delay in the needle machine of the preferred embodiment is preferably about 0-13 mm / stroke. As a result, maintaining a small delay the laminate with improved mechanical and fire retardant properties to disposal.

The Laminate with three layers can be made if the synthetic Nonwovens a different basis weight to have. The relationship the basis weights of the two synthetic nonwovens is preferably 1: 1 to 1: 5, preferably 1: 1 to 1: 3 and more preferably 1: 1 to 1: 2.

The Invention is further explained by the examples given below, wherein the laminate has a synthetic nonwoven layer and a fabric glass layer contains.

EXAMPLE

A random nonwoven fabric is made by depositing polyethylene terephthalate on a conveyor belt. Thereafter, the web is preconsolidated by needling and placing 33 stitches per cm ² . The fleece has a basis weight of 183 g / cm ² .

The Fleece is placed on a glass cloth, which is covered by a melamine resin is pre-consolidated. To make the glass fabric are warp yarns used, which include continuous glass filaments. The titer is 136 tex, the weft yarn is made on the basis of glass staple fibers and the titer is 330 tex. The chain density is four yarns per cm.

Thereafter, the two layers are joined by needle punching at 41 stitches per cm ² at a feed ratio of 12 mm / stitch. Subsequently, the laminate is subjected to a final consolidation with a styrene binder. The maximum machine direction tensile load is 514 N / 5 cm at 32.4% elongation and 457 N / 5 cm at 35.8% in the transverse direction.

While the Invention in detail with reference to its specific embodiments has been described, it is for the skilled person will appreciate that various changes and modifications made and equivalents can be used without departing from the scope of the following claims.

Claims (25)

Laminate of two or more layers, at least a nonwoven layer of organic synthetic filaments, and at least one fabric or scrim of glass fibers, preconsolidated with a binder, comprising these synthetic nonwovens and these tissues or scrims are connected by needlepunching, so that a portion of the organic synthetic filaments through the laminate passes through and emerges on the lower surface of the laminate and is there; and the laminate with a delay less than 14 mm / stroke in the needle machine is; and wherein the formed laminate of a final consolidation with an acrylate or a styrene binder has been subjected. Laminate according to claim 1, wherein the nonwoven layer made of synthetic filaments a nonwoven layer of polyester filaments is. A laminate according to claim 1, wherein the binder selected from the group is made of polyvinyl acetate and starch, urea and melamine consists. Laminate according to claim 1, wherein these synthetic Filaments in the heat shrunk. Laminate according to claim 1, wherein these synthetic Filaments are thermally precured by calendering. A laminate according to claim 1, wherein said nonwoven layer made of synthetic filaments is preconsolidated by needling. The laminate of claim 1, wherein said synthetic nonwoven layer and said fabric or scrim are joined by needling at 30-50 stitches / cm ² . A laminate according to claim 1, wherein said laminate 5 to 35 weight percent based on acrylate or styrene binder of the total weight of nonwovens made of synthetic filaments and the glass fabrics or lay for includes the final consolidation. A laminate according to claim 1, wherein said laminate 14 to 18 weight percent based on acrylate or styrene binder of the total weight of synthetic filament nonwoven fabric and the Glass fabrics or -layed for includes the final consolidation. Laminate according to claim 1, wherein said delay from 0-13 mm / stroke. A laminate according to claim 1, wherein the laminate two synthetic nonwoven layers and a glass-containing fabric wherein the glass fabric comprises weft and warp threads whose titers are differ by at least a factor of 2. A laminate according to claim 1, wherein the laminate three layers, and the nonwoven synthetic non-preloaded are. A laminate according to claim 1, wherein said glass fabric continuous glass filaments as warp yarns and glass staple yarns as weft threads includes. Laminate according to claim 1, wherein the weft threads are tapes. Laminate according to claim 1, wherein the fabric or Scrim E-fibers, C-fibers, Mixtures thereof and ECR fibers contains. A method of producing laminates having two or more layers by providing a woven or laid glass fiber, pre-bonding said fabric or scrim with a binder, applying a nonwoven fabric of synthetic filaments to said pre-consolidated fabric or scrim, and optionally applying said nonwoven to both Apply pages of fabric or jelly, creating a Sandwich assembly, this fabric and nonwoven by needling together so that a portion of the synthetic filaments passes through the laminate and emerges on the lower surface of the laminate and is applied there, and wherein the laminate with a distortion of less than 14 mm / Stroke in the needle machine is prepared, and treating the formed laminate with an acrylate or styrene binder to solidify this laminate. The method of claim 16, wherein the synthetic Filament is a polyester filament. The method of claim 16, wherein said binder selected from the group which consists of polyvinyl acetate and starch, urea and melamine. The method of claim 16, wherein said synthetic Filaments in the heat shrunk. The method of claim 16, wherein said nonwoven from synthetic filaments by calendering or by needling thermally pre-consolidated. Process according to claim 16, wherein the preconsolidation is carried out used by needling or joining by needling needles, a distance between the needle tip and the first barb from 2 to 4 mm. The method of claim 16, wherein the delay is 0 to 13 mm / stroke. The method of claim 16, wherein a fabric or a scrim fibers of C-glass, E-glass, mixtures thereof and ECR glass. Method of claiming the laminate 1 as a carrier fabric for bitumen roofing membranes or sealing membranes used. Method of claiming the laminate 13 as a carrier fabric for bitumen roofing membranes or sealing membranes used.