TW201900398A - 包含第一部分和第二部分之非織造載體材料 - Google Patents

包含第一部分和第二部分之非織造載體材料 Download PDF

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Publication number
TW201900398A
TW201900398A TW107115771A TW107115771A TW201900398A TW 201900398 A TW201900398 A TW 201900398A TW 107115771 A TW107115771 A TW 107115771A TW 107115771 A TW107115771 A TW 107115771A TW 201900398 A TW201900398 A TW 201900398A
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Taiwan
Prior art keywords
fiber layer
thermoplastic fiber
carrier material
nonwoven carrier
length
Prior art date
Application number
TW107115771A
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English (en)
Other versions
TWI785039B (zh
Inventor
吉勃特斯 赫曼森
約翰尼斯 迪瓊格
Original Assignee
荷蘭商洛＆柏奈股份有限公司
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Publication of TW201900398A publication Critical patent/TW201900398A/zh
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Publication of TWI785039B publication Critical patent/TWI785039B/zh

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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
    • B32B5/22—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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
    • B29C66/02241—Cutting, e.g. by using waterjets, or sawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/032—Mechanical after-treatments
    • B29C66/0324—Reforming or reshaping the joint, e.g. folding over
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12443—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue having the tongue substantially in the middle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1248—Interpenetrating groove joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/128—Stepped joint cross-sections
    • B29C66/1282—Stepped joint cross-sections comprising at least one overlap joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/128—Stepped joint cross-sections
    • B29C66/1284—Stepped joint cross-sections comprising at least one butt joint-segment
    • B29C66/12841—Stepped joint cross-sections comprising at least one butt joint-segment comprising at least two butt joint-segments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/14—Particular design of joint configurations particular design of the joint cross-sections the joint having the same thickness as the thickness of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B38/00—Ancillary operations in connection with laminating processes
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    • 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
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Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Civil Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

本發明涉及至少包含第一部分和第二部分之非織造載體材料，其中該第一和該第二部分至少包含兩層熱塑性纖維。該第一部分和該第二部分係在連接區域中彼此連接而形成該非織造載體材料且在該連接區域中沒有厚度和重量變異。本發明亦涉及用於連接非織造載體材料的第一和第二部分而形成連接的非織造載體材料的方法。

Description

包含第一部分和第二部分之非織造載體材料
本發明涉及至少包含兩層熱塑性纖維的非織造載體材料，其中該非織造載體材料至少包含第一部分和第二部分，其中該第一和該第二部分係經由連接區域而彼此連接而形成該非織造載體材料。本發明亦涉及用於連接非織造載體材料的第一和第二部分的方法。
在先前技術中已知有包含熱塑性纖維層的非織造載體材料。這樣的材料被用於許多應用上，例如瀝青屋頂用薄膜、屋頂用襯墊片、過濾介質用的載體、用於簇絨地毯的基礎底布和(墊)乙烯基地板覆蓋物。
在非織造載體材料的製造製程期間，會在網狀物(web)形成製程中及/或在接合製程中發生干擾(disturbances)，而在該非織造載體材料中造成品質問題而必須從該非織造載體材料拋棄品質有問題的部分，即切除。
非織造載體材料一般是以捲筒式物品的形式販售，其中就每種非織造類型及/或每種應用而言，較佳 為每捲的長度應該是相同的。在該非織造載體材料的某些製造製程期間，將熱塑性纖維從複數個捲筒(bobbin)展開(unwound)。若一些纖維在該展開階段(unwinding phase)期間斷裂，則該所得到的非織造載體材料會存在一些缺陷，例如破洞或纖維束。
將這些缺陷區域從該非織造載體材料切除或切掉並以具有正確材料性質的非織造載體材料取代。因此，將材料的不同部分以對接或彼此交疊的方式放在一起並彼此連接而產生出連續的材料。這樣的兩部分材料之間的連接造成了材料厚度較大的連接區域、或在兩部分之間存在有紡織縫合而導致局部性質不同的區域。對許多應用而言，這種連接區域中的厚度和性質變異是不期望的。
本發明的目的為提供一種改善的非織造載體材料，其至少包含第一部分和第二部分，其中該第一部分和該第二部分係經由連接區域彼此連接而沒有先前技術的缺點。本發明的目的亦為一種改善的方法，其用於將非織造載體材料的第一部分和第二部分彼此連接且沒有先前技術的缺點。
本發明的目的係藉由如請求項1的用於至少連接非織造載體材料的第一部分和第二部分的方法、和如請求項6的非織造載體材料來達成。
下文中，術語”第一熱塑性纖維層”和”第一纖維層”係作為同義詞使用。術語”第二熱塑性纖維層”和” 第二纖維層”亦作為同義詞使用。
為了避免理解不足，所請的非織造載體材料係第一非織造載體材料(稱為第一部分)和第二非織造載體材料(稱為第二部分)的組合，其係以新穎且有進步的方式彼此組合且未增加該非織造材料的厚度(特別是在該連接區域中)，或者與該非織造載體材料的其他區域相比，至少減少該連接區域中的厚度差異。
該非織造載體材料的該第一部分包含第一和第二熱塑性纖維層。然而，在第一實施例中，該第一部分的該第一和第二熱塑性纖維層係由單一的(起始)熱塑性纖維層產生。為了由單一的起始熱塑性纖維層產生出該第一和第二熱塑性纖維層，可採用兩種方法：第一方法係藉由研磨料(abrasive)移除該起始熱塑性纖維層的部分厚度，就像使用銑磨(milling)或研磨機(grinder)等技術的方法，就像例如削除(skiving)。第二方法包括分離步驟(separating step)，藉由平面地切入該起始熱塑性纖維層而產生出該第一和第二熱塑性纖維層，然後移除該第一或第二熱塑性纖維層的一部分。藉由這些產生出該第一和該第二熱塑性纖維層的方法，減少該非織造載體材料的厚度，較佳為減少到約原厚度的一半。在此實施例中，該移除及/或分離步驟產生出兩個獨立的熱塑性纖維層(第一和第二纖維層)。此實施例亦可應用於該第二部分。這表示：該第二部分亦可包含單一的起始熱塑性纖維層且在分離步驟中產生出該第二部分的第一和第二熱塑性纖維層。
在第二實施例中，該第一部分(和該第二部分)包含獨立的第一和第二熱塑性纖維層。這表示：將第一熱塑性纖維層和第二熱塑性纖維層放在一起以形成該非織造載體材料的該第一(和第二)部分。同樣地，在此實施例中，使用分離步驟來將該第一和該第二熱塑性纖維層(在該第一部分中和在該第二部分中)彼此分離。在此分離步驟期間，再度得到該兩個獨立的第一和第二熱塑性纖維層(至少在該連接區域中)。此外，能夠使用研磨方法來移除該非織造載體材料的該第一部分(和第二部分)的部分厚度而再度得到該第一(和第二)部分的第一和第二熱塑性纖維層。
較佳地，為了藉由研磨方法來移除該第一及/或第二部分的部分厚度，使用削除裝置。
較佳地，該第二部分的該第一熱塑性纖維層係由與該非織造載體材料的該第一部分的該第一熱塑性纖維層相同類型的纖維組成。
較佳地，該第二部分的該第二熱塑性纖維層係由與該非織造載體材料的該第一部分的該第二熱塑性纖維層相同類型的纖維組成。
在較佳的實施例中，該第一部分的該第二熱塑性纖維層、該第二部分的該第一熱塑性纖維層和該第二部分的該第二熱塑性纖維層，係全部由與該非織造載體材料的該第二部分的該第一熱塑性纖維層相同類型的纖維組成。
在較佳的實施例中，該第一部分的該第一纖 維層係由與該第二部分的該第一纖維層相同類型的纖維組成，且該第一部分的該第二纖維層係由與該第二部分的該第二纖維層相同類型的纖維組成。
亦較佳地，該第一部分的該第一纖維層、該第二部分的該第一纖維層、該第一部分的該第二纖維層和該第二部分的該第二纖維層係由相同類型的纖維組成。
在本發明的範圍內，應瞭解的是術語纖維意指短纖維(staple fibers)和長纖維(filaments)兩者。短纖維係具有在2至200mm範圍內特定的、相當短的長度的纖維。長纖維係具有超過200mm的長度的纖維，較佳為超過500mm，更佳為超過1000mm。長纖維甚至可能是實質上沒有盡頭的，例如當藉由連續擠出且透過紡嘴(spinneret)中的紡紗孔(spinning hole)進行長纖維的紡紗來形成時。
該纖維可以具有任何剖面形狀，包括圓形、三葉形(trilobal)、多葉形(multilobal)或矩形，後者具有寬度和高度，其中該寬度可能比該高度大得多，以至於在本實施例中該纖維為帶狀(tape)。此外，該纖維可為單成分、雙成分或甚至多成分的纖維。
該非織造載體材料可為任何類型的非織造物，例如藉由熟知的製程生產的短纖維非織造物，例如梳理製程、濕式佈層(wet-laid)製程或氣式佈層(air-laid)製程或其任何組合。該非織造載體材料亦可為由藉由熟知的紡紗接合(spunbonding)製程生產的長纖維組成的非 織造物，其中長纖維係從紡嘴擠出，然後放在輸送帶上作為長纖維的網狀物，然後接合該網狀物而形成纖維的非織造層，或藉由兩步驟製程，其中將長纖維進行紡紗並捲繞在捲筒上，較佳為以多長纖維紗線(yarn)的形式，接著進行如下步驟：將該多長纖維紗線展開並將該長纖維放在輸送帶上作為長纖維的網狀物並接合該網狀物而形成纖維的非織造載體材料。
較佳地，該第一部分及/或該第二部分的至少兩個熱塑性纖維層中的纖維為長纖維，以便對該非織造載體材料及/或該最終(含浸)產品(例如瀝青屋頂用薄膜、屋頂用襯墊片、過濾介質用的載體、用於簇絨地毯或(墊)乙烯基地板覆蓋物)提供較高的拉伸強度及/或較高的撕裂強度。
該第一部分及/或該第二部分的該至少兩個熱塑性纖維層可由佔該至少兩個纖維層中的纖維的總重量的至少50重量%的熱塑性纖維組成，較佳為至少75重量%，更佳為至少90重量%，甚至更佳為至少95重量%。增加該至少兩個纖維層中的熱塑性纖維的量便增加了拉伸強度及/或耐撕裂性且增加了該非織造載體材料及/或該最終(含浸)產品的可撓性。
在實施例中，該第一部分及/或該第二部分的該第一和該第二纖維層係由佔該纖維層中的纖維的總重量的100重量%的熱塑性纖維組成。
組成該第一及/或第二纖維層中的該熱塑性纖維的該熱塑性聚合物可為任何類型的能禁得起例如在 瀝青屋頂用薄膜、屋頂用襯墊片、過濾介質用的載體、用於簇絨地毯和(墊)乙烯基地板覆蓋物的製造製程中所受到的高溫的熱塑性聚合物。該熱塑性纖維可包含聚酯，例如聚對苯二甲酸乙二酯(PET)(基於DMT或PTA)、聚對苯二甲酸丁二酯(PBT)、聚對苯二甲酸丙二酯(PTT)、聚對萘二甲酸乙二酯(PEN)及/或聚乳酸(PLA)、聚醯胺，例如聚醯胺-6(PA6)、聚醯胺-6,6(PA6,6)及/或聚醯胺-6,10(PA6,10)、聚苯硫(PPS)、聚伸乙基亞胺(PEI)及/或聚甲醛(POM)及/或其任何共聚物或任何掺合物。
在實施例中，該非織造載體材料的厚度變異(包括該連接區域)係小於0.20mm，較佳為小於0.15mm，更佳為小於0.10mm且最佳為小於0.05mm，其係與該非織造載體材料的主要延伸方向垂直地進行測量(見圖5)，即該連接區域的平均厚度較佳為不超過該非織造載體材料的其他部分的平均厚度。該術語”小於0.15mm”包括±0.1mm的公差(tolerance)在內。該厚度係根據DIN ISO 9073-2(1996，十月)測定。
在實施例中，該連接區域的平均重量，即該連接區域中的該第一部分A和該第二部分B的合併重量，係與不包含該連接區域的該非織造載體材料的平均重量相差至多20重量%，更佳為至多10重量%，且最佳為至多5重量%。在本文中，術語”至少”代表0.5至1.5重量%的公差。
該非織造載體材料的該第一部分和該第二部分在該連接區域中一起形成了外形配合的連接(form-fit connection)。該第一部分和該第二部分像拼圖塊一樣在該連接區域中相互配合。厚度變異能藉由此外形配合的連接來縮小(由於避免在該連接區域中將第一及/或第二纖維層增加一倍)且產生出一種壓入配合(force-fit)。由於這種壓入配合，該第一部分和該第二部分經由(例如)結合技術(consolidation techniques)的永久連接比較容易(在結合期間未發生不同層的滑動(slipping))及/或得到較強的連接，結合技術係如軋平、機械針刺(mechanical needling)、水力纏絡(hydroentanglement)、超音波接合、熱接合，較佳為藉由熱氣進行的熱接合、或藉由其任何組合。
較佳地，能夠在該連接區域的機械針刺的組合後施加該連接區域的熱接合，由於該連接區域中的該第一部分與該第二部分之間的該纖維的纏絡而得到該連接區域的強度增加。
在另一實施例中，使用適合的黏結劑(binder)來改善該第一部分與該第二部分之間的接合。該黏結劑可以為化學黏結劑、如熱固性聚合物的熱黏結劑、感壓式黏著劑(adhesive)、可由壓力和熱活化的黏著劑或藉由放射線(例如藉由UV放射線)活化的黏著劑。
在實施例中，在該至少兩個纖維層之間配置條子稀洋紗(scrim)。較佳為將條子稀洋紗配置在該第一部分的該第一與第二纖維層之間、和在該第二部分的該第一與第二纖維層之間。該條子稀洋紗較佳為織造條子稀洋紗(woven scrim)或佈層條子稀洋紗(laid scrim)。該 條子稀洋紗確保了該非織造載體材料的該第一和第二纖維層中的纖維之間的距離，且可對該非織造載體材料提供改善的拉伸強度、改善的尺寸穩定性(即，減少在施加於該非織造載體材料的特定負載下的伸長率)、及/或改善的撕裂強度。關於使用條子稀洋紗的優點，申請人進一步參照WO 2015055619 A1。
在實施例中，該條子稀洋紗係由玻璃纖維或其他具有至少5GPa的高模數(modulus)纖維製成，較佳為具有至少10GPa，更佳為具有至少15GPa，更佳為具有至少20GPa，更佳為具有至少25GPa，更佳為具有至少40GPa，更佳為具有至少50GPa，最佳為具有至少75GPa。
在實施例中，該條子稀洋紗的在該載體材料的縱向方向上延伸的絲線(thread)包含高模數紗線(yarn)，例如聚酯紗線(例如聚對苯二甲酸乙二酯(PET)紗線)、聚醯胺紗線(例如聚醯胺-6(PA6)紗線)、玻璃紗線、芳香族聚醯胺紗線或碳紗線及/或其他高模數紗線或其任何組合。在較佳實施例中，使用具有以下規格的玻璃條子稀洋紗：
‧每25cm有33條經線且每25cm有21條緯線
在機器方向上：
‧纖度(Titer)：34德士(tex)
‧110~130N/5cm強度
‧2.8~3.7%斷裂伸長率
在與機器方向橫向的方向上：
‧纖度：34德士
‧68~80N/5cm強度
‧2.5~3.0%斷裂伸長率
在實施例中，可將條子稀洋紗配置在該第一部分的該第一熱塑性纖維層中，且可將條子稀洋紗配置在該非織造載體材料的該第二部分的該第二熱塑性纖維層中。在本實施例中，該連接區域將同時包含配置在該第一部分的該第一熱塑性纖維層中的該條子稀洋紗、和配置在該第二部分的該第二熱塑性纖維層中的該條子稀洋紗以在該非織造載體材料中得到改善的尺寸穩定性。
較佳地，配置在該第一部分的該第一熱塑性纖維層中的該條子稀洋紗係配置成接近該第一部分的該第一熱塑性纖維層與該第二熱塑性纖維層之間的介面，且較佳地，配置在該第二部分的該第二熱塑性纖維層中的該條子稀洋紗係配置成接近該第二部分的該第二熱塑性纖維層與該第一熱塑性纖維層之間的介面能改善在該組合的非織造載體材料的該連接區域中的該條子稀洋紗之間的負載轉移(load transfer)。當在該連接區域中外形配合的連接的結合的期間，在該連接區域中該條子稀洋紗彼此靠得更近時，將獲得在該條子稀洋紗之間的改善接合。
較佳地，配置在該第一部分的該第一熱塑性纖維層中的該條子稀洋紗係配置成與該第一部分的該第一熱塑性纖維層與該第二熱塑性纖維層之間的介面相隔一段距離，該距離小於該第一部分的該第一熱塑性纖維 層的厚度的50%，更佳為小於40%，甚至更佳為小於30%，最佳為小於20%。
可將配置在該第一部分的該第一熱塑性纖維層中的該條子稀洋紗可配置在單一起始熱塑性纖維層的厚度的中心線上，該單一起始熱塑性纖維層係在該連接區域處厚度減少小於50%，但較佳為減少至少15%，較佳為減少至少25%，更佳為減少至少30%，最佳為減少至少40%，以產生出該第一部分的該第一和該第二熱塑性纖維層。藉由將該單一起始熱塑性纖維層的厚度減少小於50%，減少該條子稀洋紗受損的風險而改善該非織造載體材料的尺寸穩定性。
較佳地，配置在該第二部分的該第二熱塑性纖維層中的該條子稀洋紗係配置成與該第二部分的該第二熱塑性纖維層與該第一熱塑性纖維層之間的介面相隔一段距離，該距離小於該第二部分的該第二熱塑性纖維層的厚度的50%，更佳為小於40%，甚至更佳為小於30%，最佳為小於20%。
可將配置在該第二部分的該第二熱塑性纖維層中的該條子稀洋紗配置在單一起始熱塑性纖維層的厚度的中心線上，該單一起始熱塑性纖維層係在該連接區域處厚度減少小於50%，但較佳為減少至少15%，較佳為減少至少25%，更佳為減少至少30%，最佳為減少至少45%，以產生出該第二部分的該第一和該第二熱塑性纖維層。藉由將該單一起始熱塑性纖維層的厚度減少小於50%，減少該條子稀洋紗受損的風險而改善該非織造 載體材料的尺寸穩定性。
先前技術的非織造載體材料可包含較佳為位於該載體材料的厚度的中心線上的條子稀洋紗。當該非織造載體材料的第一部分與第二部分之間的連接係藉由將該第一部分放置在該第二部分的頂部(top)來做成時，包含在該第一部分中的條子稀洋紗與包含在該第二部分中的條子稀洋紗之間的距離等於該非織造載體材料的第一部分或第二部分的總厚度。這種先前技術的非織造載體材料的該第一部分和該第二部分可藉由在該第一部分與該第二部分之間的介面施加膠帶(adhesive tape)，和藉由在該連接區域施加熱及/或壓力而使該黏著劑流入該非織造物的纖維與該條子稀洋紗之間來將彼此連接。然而，為了在這種先前技術的非織造載體材料中得到充分的尺寸穩定性，必須施加相當大量的黏著劑以在兩個條子稀洋紗之間建立夠強的連接，在施加熱及/或壓力後該黏著劑成為散佈在該連接區域的整個厚度上。其結果，該連接部分不能被例如瀝青或PVC塑性溶膠(plastisol)含浸，這導致在製造例如瀝青薄膜或乙烯基地板的期間出現不合格的材料，因為將會在該瀝青薄膜或乙烯基地板中看到該連接區域。
當配置在該第一部分的該第一熱塑性纖維層中的該條子稀洋紗係位於與該第一部分的該第一熱塑性纖維層與該第二熱塑性纖維層之間的介面相隔一段距離，該距離小於該第一部分的該第一熱塑性纖維層的厚度的50%及/或配置在該第二部分的該第二熱塑性纖維 層中的該條子稀洋紗係位於與該第二部分的該第二熱塑性纖維層與該第一熱塑性纖維層之間的介面相隔一段距離，該距離小於該第二部分的該第二熱塑性纖維層的厚度的50%時，則當在該連接區域中在兩個條子稀洋紗之間建立連接時，能夠減少該連接區域中的例如由膠帶所施加的黏著劑的量及/或能夠減少所施加的溫度及/或壓力。其結果，在施加熱及/或壓力後該黏著劑不會成為散佈在該連接區域的整個厚度上，且完全不會殘留在該非織造載體材料的外表面，或至少大致沒有黏著劑殘留，即該非織造載體材料的表面的小於10%被黏著劑覆蓋，這樣可用例如瀝青或PVC塑性溶膠(至少部分地)含浸該非織造載體材料，而不會在該瀝青薄膜或乙烯基地板中看到該連接區域。
當將該非織造載體材料用作用於簇絨地毯的基礎底部時，該簇絨針狀物(tufting needles)比較不會偏斜，因為該連接區域呈現出厚度增加的減少及/或包含較少的黏著劑。
此外，若將該非織造載體材料用於被瀝青含浸，便不會如先前技術所示的在縫合處發生該非織造載體的兩倍厚度形式的不均勻性。因此，用於生產瀝青屋頂用薄膜的製程，至少對用瀝青含浸該非織造載體而言，比較不會受到干擾(disturbed)。
在實施例中，該第一部分及/或該第二部分的該至少兩個纖維層包含至少兩個不同種類的單成分纖維。在實施例中，使用不同類型的單成分纖維，其中該 至少兩個不同種類的單成分纖維較佳為由具有不同熔點的不同化學結構的聚合物組成。較佳為該至少兩個不同聚合物的熔點相差至少10℃，較佳為至少20℃。更佳為該熔點相差至少50℃。這樣的產品能夠被熱接合，較佳為藉由熱氣，藉由使該連接區域中的該纖維層受到在具有較低熔點的該聚合物的熔點的範圍內的溫度。
在實施例中，該至少兩個纖維層包含由具有不同熔點的不同化學結構的兩個聚合物組成的雙成分纖維。
雙成分纖維較佳為由不同化學結構的兩個聚合物組成的纖維。在三種類型的雙成分纖維(並列型、芯鞘型和海島型的雙成分纖維)之間取出基本的區別。在實施例中，建造該雙成分纖維的兩個聚合物的熔點相差至少10℃，較佳為至少20℃。更佳為該熔點相差至少50℃。這樣的包含雙成分纖維的非織造載體材料，特別是當由並列型及/或芯鞘型雙成分纖維組成時，能夠被熱接合，較佳為藉由熱氣，藉由使該連接區域中的該纖維層受到在具有較低熔點的該聚合物的熔點的範圍內的溫度。在較佳的實施例中，該非織造載體材料主要是由該第一和第二纖維層中的芯鞘型雙成分纖維製成，較佳為長纖維。”主要”應理解為代表：該纖維層中所含的纖維的至少50%係芯鞘型雙成分纖維，較佳為至少75%，更佳為至少90%，再更佳為至少95%，最佳為100%。較佳地，在該芯/鞘雙成分纖維中該芯/鞘比位於95/5體積%與5/95體積%之間。更佳為該芯/鞘比位於50/50體積% 與95/5體積%之間。
在實施例中，該雙成分纖維的鞘包含包含聚醯胺、聚烯烴、鹵化聚烯烴及其共聚物或混合物的聚合物群組的聚合物。
在另一實施例中，該雙成分纖維的芯包含包含聚烯烴、鹵化聚烯烴、聚醯胺、聚酯及其共聚物或混合物的聚合物群組的聚合物。
在另一實施例中，對例如瀝青薄膜、簇絨地毯或乙烯基地板而言，該芯/鞘雙成分纖維的鞘主要由聚醯胺(較佳為聚醯胺-6(PA6))組成，且該芯主要由聚酯(較佳為聚對苯二甲酸乙二酯(PET))組成。
在另一實施例中，對例如簇絨地毯或過濾介質而言，該芯/鞘雙成分纖維的鞘主要由聚烯烴(較佳為聚丙烯)組成，且該芯主要由聚酯(較佳為聚對苯二甲酸乙二酯(PET))組成。
在另一實施例中，對例如瀝青薄膜、簇絨地毯、乙烯基地板或過濾介質而言，該芯/殼雙成分纖維的殼主要由聚酯(較佳為共聚聚酯(co-PET))組成，且該芯主要由聚酯(較佳為聚對苯二甲酸乙二酯(PET))組成。
在實施例中，該連接區域係與該非織造載體材料的主要方向垂直或傾斜角度地延伸。較佳地，該連接區域係與該非織造載體材料的主要延伸方向傾斜1°至30°之間(較佳為在3°與15°之間，且更佳為在5°與10°之間)的角度延伸(見圖3)。較佳地，該連接區域係在整個與機器方向橫向的方向上延伸。較佳地，該連接區域 為直線，但也包括例如鋸齒狀連接區域在內。
在另一實施例中，將該第一部分與該第二部分之間的接觸表面擴大以便在該連接區域中增加縫合強度(seam strength)。該第一部分與該第二部分的接觸表面的擴大能夠藉由以下方式得到：增加該第一部分的該第一纖維層與該第一部分的該第二纖維層的長度差異，且甚至在該第二部分中以相同方式操作。較佳地，在該第一部分與該第二部分之間的該接觸表面係藉由具有帶有交錯的不同長度的附加纖維層來擴大(見例如圖12和13)。另一種可行方式為該連接區域包含非線性形狀，譬如鋸齒狀連接區域或波浪狀連接區域。
該非織造載體材料可包含具有帶有角度β的傾斜的層邊界的第一部分、和具有與角度β互補的傾斜的層邊界的第二部分，使得該第一部分和該第二部分在該連接區域中一起形成外形配合的連接。
該非織造載體材料的該第一部分和該第二部分的該外形配合的連接可具有帶有角度β的傾斜的層邊界，該角度β係相對於該非織造載體材料的該第一部分和該第二部分的主要表面，其中該第一部分和該第二部分係經由該傾斜的層邊界連接，導致該第一部分和該第二部分的主要表面係配置在單一平面中，如例如圖10所示。
或者是，該非織造載體材料的該第一部分和該第二部分的外形配合的連接可呈現出具有帶有角度β的傾斜的層邊界的第一部分和第二部分，該角度β係相 對於該非織造載體材料的該第一部分和該第二部分的主要表面，其中該第一部分和該第二部分係經由該第一部分的主要表面和該第二部分的主要表面連接，如例如圖11所示。此配置可將該第一部分經由該第一部分和該第二部分的主要表面連接至該第二部分，該第一部分和該第二部分並未經過處理以移除材料而減少該厚度，可改善接合。雖然該組合的非織造載體材料的主要表面可能在該連接區域中呈現偏移(shift)，但是，與該非織造載體材料的其他部分相比，該連接區域的厚度仍能呈現出均等的厚度。
提供一種方法，用於連接包含具有厚度的第一部分(A)和具有厚度的第二部分(B)的非織造載體材料，其中該第一部分(A)和該第二部分(B)至少包含第一和第二熱塑性纖維層(A1、A2；B1、B2)，其中以該第一部分(A)和該第二部分(B)在該連接區域中一起形成外形配合的連接的方式，將該第一部分(A)的部分厚度和第二部分(B)的部分厚度移除而形成該第一熱塑性纖維層(A1、B1)和該第二熱塑性纖維層(A2、B2)。
較佳地，該第一部分(A)及/或第二部分(B)的部分厚度的移除係藉由熟悉技藝者所知的削除來進行。
在實施例中，該方法包含分離方法，其係在移除該第一熱塑性纖維層(A1、B1)和該第二熱塑性纖維層(A2、B2)的一部分之前進行，其中該第一部分A係在分離步驟中，被部分地分離成該第一熱塑性纖維層(A1)和該第二熱塑性纖維層(A2)，且該第二部分B係在分離 步驟中，被部分地分離成該第一熱塑性纖維層(B1)和該第二熱塑性纖維層(B2)，其中該第一部分(A)的該第一和該第二熱塑性纖維層(A1、A2)和該第二部分(B)的該第一和該第二熱塑性纖維層(B1、B2)係在該分離步驟中被彼此分離。
在實施例中，在用於連接包含第一部分(A)和第二部分(B)的非織造載體材料的方法中，其中該第一部分(A)和該第二部分(B)兩者都至少包含第一(A1、B1)和第二熱塑性纖維層(A2、B2)，該第一部分(A)係在分離步驟中，被部分地分離成該第一部分(A)的該第一熱塑性纖維層(A1)和該第二熱塑性纖維層(A2)，且該第二部分(B)係在分離步驟中，被部分地分離成該第一熱塑性纖維層(B1)和該第二熱塑性纖維層(B2)，其中該第一部分(A)的該第一熱塑性纖維層(A1)和該第二熱塑性纖維層(A2)和該第二部分(B)的該第一熱塑性纖維層(B1)和該第二熱塑性纖維層(B2)係在該分離步驟中被彼此分離，且以該第一部分(A)的該第一熱塑性纖維層(A1)的長度係與該第一部分(A)的該第二熱塑性纖維層(A2)的長度不同，且該第二部分(B)的該第一熱塑性纖維層(B1)的長度係與該第二部分(B)的該第二熱塑性纖維層(B2)的長度不同的方式，將該第一部分(A)的部分厚度和第二部分(B)的部分厚度移除而形成第一熱塑性纖維層(A1、B1)及/或第二熱塑性纖維層(A2、B2)，其中該第一部分的該第一熱塑性纖維層(A1)的長度和該第二部分的該第一熱塑性纖維層(B1)的長度的總和，係等於該第一部分的該第 二熱塑性纖維層(A2)的長度和該第二部分的該第二熱塑性纖維層(B2)的長度的總和，其中在連接區域中將該第一部分和該第二部分連接而形成連接的非織造載體材料。
根據本揭露的方法可應用於非織造載體材料的該第一部分和該第二部分的兩個不同的實施例。在第一實施例中，該非織造載體材料的該第一部分包含兩個獨立的熱塑性纖維層，且該第二部分亦同，而在第二實施例中，使用單一的起始熱塑性纖維層，其已如上所述被(部分地，這代表至少在該將來的連接區域的區段(zone)中)分離成兩個熱塑性纖維層。
在用於該第一實施例的分離步驟中，該兩個獨立的熱塑性纖維層被彼此分離(在將該纖維層一起放在彼此的頂部之前，不論是否結合)。在用於該第二實施例的分離步驟中，至少在該將來的連接區域的長度上將該單一的起始熱塑性纖維層分離成兩個不同的層(第一和第二熱塑性纖維層)。較佳地，從該單一的起始熱塑性纖維層所產生的該第一熱塑性纖維層的厚度及/或重量係等於該第二熱塑性纖維層的厚度及/或重量(在該第一部分及/或該第二部分中)。
較佳地，該第一部分的該第一熱塑性纖維層的長度係與該第一部分的該第二熱塑性纖維層的長度相差至少0.5cm，較佳為至少1cm，更佳為至少2cm。較佳地，該第二部分的該第一熱塑性纖維層的長度係與該第二部分的該第二熱塑性纖維層的長度相差至少0.5cm， 較佳為至少1cm，更佳為至少2cm。
在實施例中，該連接區域中的該非織造載體材料的該第一部分和該第二部分的(接著的)永久連接係藉由結合技術形成。為此，較佳的技術包含軋平、機械針刺、水力纏絡、超音波接合、熱接合，較佳為藉由熱氣進行的熱接合、或其任何組合。
較佳地，能夠在該連接區域的機械針刺的組合後施加該連接區域的熱接合，由於該第一部分與該第二部分之間的該纖維的纏絡而在該連接區域中增加強度。
在另一實施例中，使用適合的黏結劑來改善該非織造載體材料的該第一部分與該第二部分之間的接合。該黏結劑可為化學黏結劑或如熱固性聚合物的熱黏結劑、可由壓力和熱活化的黏著劑或藉由放射線(例如藉由UV放射線)活化的黏著劑。
在實施例中，該連接區域係與該非織造載體材料的主要延伸方向垂直或傾斜角度地(較佳為傾斜20°)延伸。
較佳地，使用分離裝置來將該第一部分的該第一熱塑性纖維層與該第二熱塑性纖維層彼此分離，和將該第二部分的該第一熱塑性纖維層與該第二熱塑性纖維層彼此分離。
經由圖式進一步說明本發明。
A‧‧‧第一部分
A1‧‧‧第一熱塑性纖維層
A2‧‧‧第二熱塑性纖維層
A3‧‧‧第三熱塑性纖維層
A4‧‧‧第四熱塑性纖維層
B‧‧‧第二部分
B1‧‧‧第一熱塑性纖維層
B2‧‧‧第二熱塑性纖維層
B3‧‧‧第三熱塑性纖維層
B4‧‧‧第四熱塑性纖維層
1‧‧‧非織造載體材料
3‧‧‧連接區域
4‧‧‧條子稀洋紗
5‧‧‧分離裝置
α‧‧‧角度
β‧‧‧角度
圖1和2(A+B)係示意地顯示先前技術的非織造載體材料的兩個部分的組合。
圖3係示意地顯示在俯視下具有連接區域的非織造載體材料。
圖4係示意地顯示非織造載體材料的第一部分和第二部分。
圖5係示意地顯示根據圖4的該非織造載體材料的第一和第二部分的連接。
圖6和7係示意地顯示該非織造載體材料的第一和第二部分的不同實施例。
圖8係示意地顯示第一熱塑性纖維層和第二熱塑性纖維層的分離步驟。
圖9係示意地顯示具有傾斜的層邊界的該非織造載體材料的第一部分和第二部分。
圖10和11係示意地顯示具有傾斜的層邊界的該非織造載體材料的第一部分和第二部分的連接。
圖12和13係示意地顯示分別具有帶有交錯的不同延伸的四層、三層纖維的非織造載體材料的第一部分和第二部分。
圖14(A+B)係示意地顯示該非織造載體材料的第一部分和第二部分，其中在該第一部分的該第一熱塑性纖維層中配置條子稀洋紗，且在該非織造載體材料的該第二部分的該第二熱塑性纖維層中配置條子稀洋紗。
圖1中，示意地顯示非織造載體材料1的第 一部分A和非織造載體材料1的第二部分B的連接(先前技術)。第一部分A具有第一熱塑性纖維層A1和第二熱塑性纖維層A2。該第二部分B也具有第一熱塑性纖維層B1和第二熱塑性纖維層B2。為了在連接區域3中連接該第一部分A和該第二部分B，將該第一部分A放置在該第二部分B的頂部。在該連接區域3中配置四個纖維層。由於此，該非織造載體材料1的厚度和重量在該連接區域3中增加。
在圖2A和2B中顯示先前技術的另一實施例。該非織造載體材料1包含具有單一纖維層的第一部分A和也具有單一纖維層的第二部分B。將部分A放置在部分B的頂部，然後部分A、B兩者被永久結合，例如藉由使用熱線(hot wire)或超音波接合/切割步驟來同時地進行切割和將部分A和部分B結合在一起。之後，將部分A和部分B折開(folded open)，其中它們在該連接區域3中被連接。同樣地，在此實施例中，該非織造載體材料1的厚度(和重量)在該連接區域3中增加。此外，該連接區域處的該非織造載體材料的強度比該非織造載體材料的其他部分低。
圖3中，顯示根據本揭露的非織造載體材料1的俯視圖。該非織造載體材料1包含第一部分A和第二部分B。該第一部分A和該第二部分B係在連接區域3中彼此連接。該連接區域3係與該非織造載體材料1的主要延伸方向(見圖5中的箭頭X)垂直地、或與該非織造載體材料1的主要延伸方向(箭頭X)傾斜角度α地延 伸。
圖4顯示包含具有第一纖維層A1和第二纖維層A2的第一部分A、和具有第一纖維層B1和第二纖維層B2的第二部分B的非織造載體材料1的側視圖。該第一部分A的該第一纖維層A1具有與該第一部分A的該第二纖維層A2不同的長度。該第二部分B的該第一纖維層B1也具有與該第二部分B的該第二纖維層B2不同的長度。然而，該第一部分A的該第一纖維層A1的長度和該第二部分B的該第一纖維層B1的長度的總和係等於該第一部分A的該第二纖維層A2的長度和該第二部分B的該第二纖維層B2的長度的總和。由於此，該第一部分A和該第二部分B就像拼圖塊一樣相互配合。
圖5顯示圖4的該第一部分A和該第二部分B的連接而產生非織造載體材料1。該第一部分A和該第二部分B具有外形配合的連接，其中，沒有厚度變異發生(與該非織造載體材料1的主要延伸方向(箭頭X)垂直地(箭頭Y)測量)。由於此外形配合的連接，也產生出一種壓入配合連接，並能夠容易地將該第一部分A和該第二部分B(永久地)結合且在該製程期間沒有一個以上的纖維層滑動。該所得到的材料係連接的非織造載體材料1。
圖6顯示圖4和5的實施例，其中在該熱塑性纖維層A1、A2和B1、B2之間配置條子稀洋紗4。該條子稀洋紗係配置在該第一部分和第二部分A、B的該 第一與第二纖維層A1、A2、B1、B2之間，或僅有該第一部分A或該第二部分B包含條子稀洋紗4(在該纖維層之間)。在該第二實施例中，移除步驟也從該第一部分或該第二部分A、B移除該條子稀洋紗。
圖7顯示每個部分具有超過2個熱塑性纖維層的本揭露的實施例。該第一部分A包含第一熱塑性纖維層A1、第二熱塑性纖維層A2和第三熱塑性纖維層A3。該第一熱塑性纖維層A1的長度係與該第二和第三熱塑性纖維層A2、A3的長度不同。因此同樣地，在本範例中，該第一部分A的該第一纖維層A1的長度和該第二部分B的該第一纖維層B1的長度的總和係等於該第一部分A的該第二纖維層A2(A3)的長度和該第二部分B的該第二纖維層B2(B3)的長度的總和。因此，對在一個部分中包含超過兩個纖維層的非織造載體材料而言，本發明也能發揮作用。應瞭解的是，一個以上的層A1、A2、A3、B1、B2和B3能夠由纖維以外的其他材料製成(例如箔)。
圖8示意地顯示分離製程。該第一部分A包含第一熱塑性纖維層A1和第二熱塑性纖維層A2。分離裝置5將該第一熱塑性纖維層A1和該第二熱塑性纖維層A2部分地彼此分離，且該第一熱塑性纖維層A1及/或該第二熱塑性纖維層A2的一部分被移除，較佳為藉由切割來移除。對該非織造載體材料1的該第二部分B(未顯示在圖8中)進行相同的程序。其中，該第一部分A和該第二部分B的該第一纖維層A1(B1未顯示在圖8中)和該第 二纖維層A2(B2未顯示在圖8中)係以所揭露的方式形成而產生外形配合的連接(如圖4、6、7)。之後，將該第一部分A和該第二部分B彼此連接(見圖3、5)。將該第一部分A和該第二部分B被彼此連接的該區域稱為該連接區域3(未顯示在圖8中)。該分離裝置5係分離機的一部分。例如，Fortuna GmbH公司販售這種分離機。
然後實現所述的外形配合的連接(像拼圖塊一樣)的方法包括分離和切割以外的其他方法。
圖9顯示具有帶有角度β的傾斜的層邊界的非織造載體材料的第一部分A和第二部分B的側視圖。
圖10顯示非織造載體材料的第一部分A和第二部分B的連接的實施例的側視圖，其中該連接區域3係根據該非織造載體材料的該第一部分A和第二部分B的主要表面，帶有角度β的傾斜的連接區域。
圖11顯示非織造載體材料的第一部分A和第二部分B的連接的側視圖，其中具有帶有角度β的傾斜的層邊界的該第一部分A和該第二部分B係在該第一部分A和該第二部分B的主要表面上、在該連接區域3中連接。以該連接區域中的該所連接的層的厚度等於該整個非織造載體材料的厚度的方式連接該第一部分A和第二部分B。
圖12顯示第一部分A和第二部分B的側視圖，其中該第一部分A和該第二部分B各自包含四層纖維層(A1~A4和B1~B4)。該第一纖維層A1(B1)具有與該第二纖維層A2(B2)不同的長度。然後，該第二纖維層 A2(B2)具有與該第三纖維層A3(B3)不同的長度，且該第三纖維層A3(B3)也具有與該第四纖維層A4(B4)不同的長度。該層之間的長度差異是交錯的，因而得到拉鏈狀外形。由此，該偶數層A2(B2)和A4(B4)及/或該非偶數層A1(B1)和A3(B3)不需要相同的長度。全部纖維層的該纖維層的長度的總和是相等的。
圖13顯示第一部分A和第二部分B的側視圖，其中該第一部分A和該第二部分B各自包含三層纖維層(A1~A3和B1~B3)。該第一纖維層A1(B1)具有與該第二纖維層A2(B2)不同的長度。然後，該第二纖維層A2(B2)具有與該第三纖維層A3(B3)不同的長度。該層之間的長度差異是交錯的，因而得到拉鏈狀外形。由此，該偶數層A2(B2)不需要相同的長度。全部纖維層的該纖維層的長度的總和是相等的。
圖14示意地顯示該非織造載體材料的第一部分和第二部分，其中在該第一部分的該第一熱塑性纖維層中配置條子稀洋紗，且在該非織造載體材料的該第二部分的該第二熱塑性纖維層中配置條子稀洋紗。圖14A中，將條子稀洋紗(虛線)配置在該第一部分的該第一熱塑性纖維層A1中，接近該第一部分的該第一熱塑性纖維層A1與該第二熱塑性纖維層A2之間的介面。也將條子稀洋紗(虛線)配置在該第二部分的該第二熱塑性纖維層B2中，接近該第二部分的該第二熱塑性纖維層B2與該第一熱塑性纖維層B1之間的介面。當在圖14B中，將外形配合的連接形成在該連接介面時，該條子稀洋紗 係接近地配置在一起，此舉改善了該非織造載體材料中的兩個條子稀洋紗之間的負載轉移。

Claims (15)

  1. 一種用於連接包含具有厚度的第一部分(A)和具有厚度的第二部分(B)的非織造載體材料(1)的方法，其中該第一部分(A)和該第二部分(B)至少包含第一和第二熱塑性纖維層(A1、A2；B1、B2)，其中以該第一部分(A)和該第二部分(B)在該連接區域中一起形成外形配合的連接(form-fit connection)的方式，將該第一部分A的部分厚度和第二部分B的部分厚度移除而形成該第一熱塑性纖維層(A1、B1)和該第二熱塑性纖維層(A2、B2)。
  2. 如請求項1的方法，其中該第一部分(A)的該第一熱塑性纖維層(A1)的長度係與該第一部分(A)的該第二熱塑性纖維層(A2)的長度相差至少0.5cm，較佳為至少1cm，更佳為至少2cm，且該第二部分(B)的該第一熱塑性纖維層(B1)的長度係與該第二部分(B)的該第二熱塑性纖維層(B2)的長度相差至少0.5cm，較佳為至少1cm，更佳為至少2cm，其中該第一部分(A)的該第一熱塑性纖維層(A1)的長度和該第二部分(B)的該第一熱塑性纖維層(B1)的長度的總和係等於該第一部分(A)的該第二熱塑性纖維層(A2)的長度和該第二部分(B)的該第二熱塑性纖維層(B2)的長度的總和，其中，之後將該第一部分(A)和該第二部分(B)在連接區域(3)中連接而形成連接的非織造載體材料。
  3. 如請求項1或2的方法，其中該連接區域(3)中的該第一部分(A)和該第二部分(B)的永久連接係藉由結合技 術(consolidation techniques)形成，該結合技術較佳為選自包含軋平、機械針刺(mechanical needling)、水力纏絡(hydroentanglement)、超音波接合、熱接合，較佳為藉由熱氣進行的熱接合、或藉由其任何組合的群組。
  4. 如請求項1至3的方法，其中該連接區域(3)係與該非織造載體材料(3)的主要延伸方向(X)垂直或傾斜角度(α)地延伸，該傾斜角度(α)較佳為20°。
  5. 如請求項1至4的方法，其中使用分離裝置來將該第一和該第二部分(A、B)中的該第一熱塑性纖維層(A1、B1)與該第二熱塑性纖維層(A2、B2)分離。
  6. 一種非織造載體材料(1)，可藉由如請求項1至5中任一項的方法得到，至少包含具有厚度的第一部分(A)和具有厚度的第二部分(B)，其中該第一部分(A)和該第二部分(B)至少包含第一和第二熱塑性纖維層(A1、A2、B1、B2)，其中該第一部分(A)和該第二部分(B)係經由連接區域(3)彼此連接而形成該非織造載體材料(1)，其特徵為該第一部分(A)和該第二部分(B)在該連接區域(3)中一起形成外形配合的連接。
  7. 如請求項6的非織造載體材料，其中該第一部分(A)的該第一熱塑性纖維層(A1)的長度係與該第一部分(A)的該第二熱塑性纖維層(A2)的長度相差至少0.5cm，較佳為至少1cm，更佳為至少2cm，且該第二部分(B)的該第一熱塑性纖維層(B1)的長度係與該第二部分(B)的該第二熱塑性纖維層(B2)的長度相差至少0.5cm，較 佳為至少1cm，更佳為至少2cm，其中該第一部分(A)的該第一熱塑性纖維層(A1)的長度和該第二部分(B)的該第一熱塑性纖維層(B1)的長度的總和係等於該第一部分(A)的該第二熱塑性纖維層(A2)的長度和該第二部分(B)的該第二熱塑性纖維層(B2)的長度的總和。
  8. 如請求項6至7中任一項的非織造載體材料(1)，其中與該非織造載體材料(1)的主要延伸區域(箭頭X)垂直地(箭頭Y)測量的該非織造載體材料(1)的厚度變異係大致小於0.15mm。
  9. 如請求項6至8中任一項的非織造載體材料(1)，其中該連接區域(3)的平均重量係與不包含該連接區域(3)的該非織造載體材料(1)的平均重量相差至多20重量%。
  10. 如請求項6至9中任一項的非織造載體材料(1)，其中將條子稀洋紗(4)配置在該第一部分(A)和第二部分(B)的至少該第一與第二熱塑性纖維層(A1、A2、B1、B2)之間。
  11. 如請求項9的非織造載體材料(1)，其中該條子稀洋紗(4)係由玻璃纖維或具有至少5GPa的高模數(modulus)纖維製成，更佳為具有至少10GPa，更佳為具有至少15GPa，更佳為具有至少20GPa，更佳為具有至少25GPa，更佳為具有至少40GPa，更佳為具有至少50GPa，最佳為具有至少75GPa。
  12. 如請求項6至11中任一項的非織造載體材料(1)，其中該第一部分(A)和該第二部分(B)的至少該第一和第 二熱塑性纖維層(A1、A2、B1、B2)包含兩種單成分纖維或包含雙成分纖維。
  13. 如請求項12的非織造載體材料(1)，其中該兩種單成分纖維係由具有不同熔點的不同化學結構的聚合物組成。
  14. 如請求項12的非織造載體材料(1)，其中該雙成分纖維係由具有不同熔點的不同化學結構的兩個聚合物組成。
  15. 如請求項6至14中任一項的非織造載體材料(1)，其中該連接區域(3)係與該非織造載體材料(1)的主要延伸方向(箭頭X)垂直或傾斜角度(α)地延伸。
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EP3621800B1 (en) 2022-03-02
KR20230104992A (ko) 2023-07-11
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JP2023065399A (ja) 2023-05-12
KR102653974B1 (ko) 2024-04-05
KR20200005563A (ko) 2020-01-15
TWI785039B (zh) 2022-12-01
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