RU2798544C1 - Method for producing non-woven material - Google Patents

Abstract

FIELD: construction materials.

SUBSTANCE: method for the production of non-woven material is claimed, which relates to building materials for residential, public and industrial buildings and structures, while the method for the production of non-woven material includes polyester staple PET fiber, the length of which is 30-40 mm, from which layers of non-woven fabric are formed, the resulting layers are fastened non-woven fabric by needle punching, then the non-woven fabric is successively passed through two calenders, the temperature of the first calender is selected from the range of 210-240°C, and the temperature of the second calender is chosen from the range of 200-230°C, wherein the first calender is in contact with the top layer of the non-woven material, and the second calender is in contact with the bottom layer of the non-woven material.

EFFECT: reduced elasticity of the fiber while maintaining the mechanical strength of the non-woven material when it is installed using a drill, screw or self-tapping screw.

2 cl, 1 dwg, 1 tbl, 12 ex

Description

The invention relates to the field of building materials for residential, public and industrial buildings and structures.

A common disadvantage of non-woven materials used as a separating fabric in roof structures is the winding of the fibers of the material on a screw, drill or self-tapping screw when it is attached to a frame or base. Moreover, this problem is present even when drilling through the material, including when drilling through the final waterproofing or roof coating. In this case, the roofing material is strongly contracted and may tear, which is unacceptable. At the same time, winding the material during installation greatly reduces the speed of working with it.

For example, a method for the production of non-woven material is known (Japanese patent No. 2009167566, publ. 30.07.2009), which consists in using polyester spatula fibers, from which the middle part of the web is formed, also using polyester or polyolefion fibers with an LOI value of 25 or less, from which the inner and outer shell of the web is formed, then these layers are connected to each other by means of a needle punch and heat treatment of the resulting web is carried out using a hot calender with a temperature of 170°C or less.

Heat treatment at the final stage of non-woven fabric production makes it possible to increase its mechanical strength without breaking the fabric when it is captured by the fastener during operation.

However, the considered nonwoven material, according to Japanese Patent No. 2009167566, is not intended for use as a roofing material. At the same time, the specified document does not say anything about the non-winding of the fiber on the tool.

A non-woven material is known (RF patent No. 186823, publ. 02/05/2019), the production method of which is chosen as the closest analogue to the claimed solution. The method consists in producing a non-woven material using a glass fiber filler enclosed in a sealed shell of non-woven polypropylene, then the obtained material layers are fastened around the perimeter by laser or high-frequency welding or thermal bonding, and stitching is performed over the area of the material with spot circular seams.

When drilling such material during installation inside circular spot welds, there is no winding of the fiber around the drill. This moment is explained by the fact that the circular seam cuts the fabric with a short fiber inside the circles.

However, the disadvantage of the considered method for the production of non-woven fabric is the production of a material having a short fiber only in a certain area. If a drill, screw or self-tapping screw gets outside the specified zone, the sheet will also be wound on the tool, which will complicate and slow down roofing work.

The technical problem of the present invention is the creation of a method for the production of non-woven material, which makes it possible, when mounting the resulting non-woven material, to exclude the winding of its fibers on a drill, screw or self-tapping screw with subsequent rupture of the web, as well as simplifying and accelerating the process of such installation.

The technical result is to increase the reliability of the resulting non-woven material during its installation using a drill, screw or self-tapping screw by reducing the elasticity of the fiber while maintaining its mechanical strength.

The technical result is achieved using a method for the production of non-woven material, which consists in using polyester staple fiber PET, the length of which is 30-40 mm, forming layers of non-woven fabric, fastening the resulting layers of non-woven fabric with a needle punch, then the non-woven fabric is sequentially passed through two calenders , wherein the temperature of the first calender is selected from the range of 210-240°C, and the temperature of the second calender is selected from the range of 200-230°C, while the first calender is in contact with the upper layer of the nonwoven material, and the second calender is in contact with the lower layer of the nonwoven material.

Staple fiber implies the use of a fiber of limited length in accordance with GOST 10213.4-2002 “Staple fiber and chemical tow. Methods for determining the length.

At the selected heating temperature of the first and second calenders, the length of the polyester staple PET fiber is 30-40 mm. As the fiber length increases, the fabric must be subjected to more intense heating, which leads to a greater loss of fiber plasticity. Such a canvas, when bent, will begin to crack and fall apart.

PET polyester staple fiber is a recycled polyester fiber with weak molecular bonds. The temperature set according to the method on the first and second calenders is sufficient for heat treatment of such fiber and ensuring its non-winding on the tool. In the case of using a virgin fiber (PET or PP), where the bond between molecules is stronger, it is necessary to set higher temperatures for its heat treatment, which, among other things, requires more energy and other significant economic costs.

Layers of non-woven material from staple fiber are obtained in a standard way, for example, using the methods presented in the article "Technologies for the production of non-woven materials using PET" (Polymer Materials magazine. No. 1, 2021. S. 28-34, Internet resource http ://www.polymerbranch.com/7ba6d33c373fea56b7258003b16c68e5/5958e9069e66c44a89476d383336330c/magazineclause.pdf).

To bond the layers of nonwoven material according to the claimed method, triple needle punching is used, where the needle punch density on the first needle punch machine is 30-50 punctures per cm ² , the needle punch density on the second needle punch machine is 90-120 punctures per cm ² , the needle punch density on the second needle punch machine is 80-100 punctures per cm ² .

Due to the sequential arrangement of the calenders, the sequence of passing the upper and lower layers of the nonwoven material through them, as well as the temperature difference of both calenders, uniform heat setting of the fibers of the nonwoven material is achieved throughout its entire thickness. In this case, there is a uniform reduction in the elasticity of the fiber, ensuring its non-winding on a drill or self-tapping screw and eliminating the possibility of tearing the web during its installation.

The figure shows an installation containing the first 1 and the second 2 heated calenders installed one above the other.

Polyester staple PET fiber undergoes triple thermal fixation (heating) during the manufacturing process, while the fiber is heated twice during the manufacture of the fiber itself, where the primary heating allows you to stretch the fiber and give it the necessary strength, and the second heating removes excess elongation.

The third and final heating through the successive use of calenders with the indicated temperature difference makes it possible to reduce the plasticity of the fiber, but to such an extent that the resulting non-woven fabric does not crack during deformation.

In this case, the non-woven fabric after bonding with a needle punch is fed to the first 1 heated calender, where it undergoes heat treatment. The upper part 3 of the non-woven fabric is adjacent to the first calender 1 on its right side, as a result of which it warms up more than the lower part 4 of the non-woven fabric. Then, the non-woven fabric is fed to the second calender 2 so that it passes on the left side of the second calender 2 . When this lower part 4 is in direct contact with the surface of the second calender 2 and warms up more than the upper part 3 of the non-woven fabric. But, since the non-woven fabric before entering the second calender 2 was already partially heated on the first calender 1, the temperature of the second calender 2 is set below the temperature of the first calender 1, thus “warming up” the non-woven material from the side of its lower part. That is, the temperature difference between the second 2 and the first 1 calenders is set to ensure uniform fusing throughout the thickness of the nonwoven fabric.

As tests have shown, at a temperature of the first calender equal to 210-240°C, and a temperature of the second calender equal to 200-230°C, the fiber of the nonwoven material loses a significant part of its plasticity, which ensures its non-winding and high reliability of the nonwoven material during installation.

Examples 1-12 show research data on a non-woven material obtained using different temperatures of the first and second calenders.

For studies according to examples 1-6, a non-woven material made of PET polyester fiber with a surface density of 150 g/m ² was used, the length of the polyester fiber was chosen to be 30 mm.

For studies according to examples 7-12, a non-woven material made of PET polyester fiber with a surface density of 150 g/m ² was used, the length of the polyester fiber was chosen to be 40 mm.

All studies were carried out using a U TS 110MN-5 1-U tensile testing machine.

Table 1 shows the quality parameters that the nonwoven material obtained during manufacture must comply with in order for it to have the property of non-winding on a drill or self-tapping screw, but at the same time retain mechanical strength.

Example 1

First calender temperature: 200°C

Second calender temperature: 190°C

Breaking load: along the length - 5.30 kN/m, along the width - 5.30 kN/m

Relative elongation at maximum load: length - 105%, width - 126%.

Weight unevenness: 15.7%

Thickness under load: 0.38

Tearing strength: along the length - 42 N, along the width - 42 N.

Thus, the fibers of the obtained non-woven fabric have excessive elongation and high mechanical strength, that is, in this case, the non-winding property is not ensured.

Conclusion: the resulting material is not recommended for use in roofing.

Example 2

First calender temperature: 210°C

Second calender temperature: 200°C

Breaking load: along the length - 4.95 kN/m, along the width - 4.95 kN/m

Relative elongation at maximum load: along the length - 95%, along the width - 115%.

Weight unevenness: 14.9%

Thickness under load: 0.41

Tearing strength: along the length - 35.6 N, along the width - 35.6 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 3

First calender temperature: 220°C

Second calender temperature: 210°C

Breaking load: along the length - 4.80 kN/m, along the width - 4.80 kN/m

Relative elongation at maximum load: along the length - 87%, along the width - 112%.

Weight unevenness: 14.6%

Thickness under load: 0.42

Tearing strength: along the length - 37.5 N, along the width - 37.5 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 4

First calender temperature: 230°C

Second calender temperature: 220°C

Breaking load: along the length - 4.66 kN/m, along the width - 4.66 kN/m

Relative elongation at maximum load: along the length - 78%, along the width - 106%.

Weight unevenness: 14.4%

Thickness under load: 0.43

Tearing strength: along the length - 37.6 N, along the width - 37.6 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 5

First calender temperature: 240°C

Second calender temperature: 230°C

Breaking load: along the length - 4.43 kN / m, along the width - 4.43 kN / m

Relative elongation at maximum load: along the length - 68%, along the width - 98%.

Weight unevenness: 14.8%

Thickness under load: 0.44

Tearing strength: along the length - 38.8 N, along the width - 38.8 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 6

First calender temperature: 250°C

Second calender temperature: 240°C

Breaking load: along the length - 3.9 kN/m, along the width - 3.9 kN/m

Relative elongation at maximum load: along the length - 62%, along the width - 94%.

Mass unevenness: 15.0%

Thickness under load: 0.46

Tearing strength: along the length - 40.5 N, along the width - 40.5 N.

Thus, the fibers of the obtained nonwoven fabric have the required elongation, but do not have the necessary mechanical strength, which leads to fiber cracking.

Conclusion: the resulting material is not recommended for use in roofing.

Example 7

First calender temperature: 200°C

Second calender temperature: 190°C

Breaking load: along the length - 5.30 kN/m, along the width - 5.30 kN/m

Relative elongation at maximum load: length - 104%, width - 125%.

Weight unevenness: 15.5%

Thickness under load: 0.37

Tearing strength: along the length - 41.9 N, along the width - 41.9 N.

Thus, the fibers of the obtained non-woven fabric have excessive elongation and high mechanical strength, that is, in this case, the non-winding property is not ensured.

Conclusion: the resulting material is not recommended for use in roofing.

Example 8

First calender temperature: 210°C

Second calender temperature: 200°C

Breaking load: along the length - 4.94 kN / m, along the width - 4.94 kP / m

Relative elongation at maximum load: along the length - 94.5%, along the width - 114%.

Weight unevenness: 14.9%

Thickness under load: 0.42

Tearing strength: along the length - 35.5 N, along the width - 35.5 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 9

First calender temperature: 220°C

Second calender temperature: 210°C

Breaking load: along the length - 4.80 kN/m, along the width - 4.80 kN/m

Relative elongation at maximum load: along the length - 86.5%, along the width - 111%.

Weight unevenness: 14.6%

Thickness under load: 0.42

Tearing strength: along the length - 37.4 N, along the width - 37.4 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 10

First calender temperature: 230°C

Second calender temperature: 220°C

Breaking load: along the length - 4.66 kN/m, along the width - 4.66 kN/m

Relative elongation at maximum load: along the length - 77%, along the width - 105%.

Weight unevenness: 14.3%

Thickness under load: 0.43

Tearing strength: along the length - 37.6 N, along the width - 37.5 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 11

First calender temperature: 240°C

Second calender temperature: 230°C

Breaking load: along the length - 4.43 kN / m, along the width - 4.43 kN / m

Relative elongation at maximum load: along the length - 68%, along the width - 97%.

Weight unevenness: 14.8%

Thickness under load: 0.44

Tearing strength: along the length - 38.7 N, along the width - 38.8 N.

Thus, the fibers of the obtained non-woven fabric have the required elongation and the necessary mechanical strength, that is, in this case, the non-winding property is ensured.

Conclusion: the resulting material is recommended for use in roofing.

Example 12

First calender temperature: 250°C

Second calender temperature: 240°C

Breaking load: along the length - 3.9 kN/m, along the width - 3.9 kN/m

Relative elongation at maximum load: along the length - 61%, along the width - 94%.

Mass unevenness: 15.0%

Thickness under load: 0.47

Tearing strength: along the length - 40.6 N, along the width - 40.6 N.

Thus, the fibers of the obtained nonwoven fabric have the required elongation, but do not have the necessary mechanical strength, which leads to fiber cracking.

Conclusion: the resulting material is not recommended for use in roofing.

As a result, it has been experimentally established that the temperature range of 210-240°C is optimal for the first calender, while the temperature range of 200-230°C is optimal for the second calender.

Non-woven material in the case of such a final sequential heat treatment of its upper and lower parts has the necessary strength characteristics, which increases the reliability and service life of the fabric, and also contributes to its faster and easier installation when installing pitched roofs in low-rise cottage construction and operated flat roofs in industrial civil construction.

Claims (2)

1. A method for the production of non-woven material, which consists in using polyester staple fiber PET, the length of which is 30-40 mm, forming layers of non-woven fabric, fastening the resulting layers of non-woven fabric with a needle punch, then the non-woven fabric is sequentially passed through two calenders, and the temperature of the first the calender is selected from the range of 210-240°C, and the temperature of the second calender is selected from the range of 200-230°C, while the first calender is in contact with the top layer of the nonwoven material, and the second calender is in contact with the bottom layer of the nonwoven material. 2. The production method according to claim 1, which consists in using triple needle punching, where the needle punch density on the first needle punch machine is 30-50 punctures per cm ² , the needle punch density on the second needle punch machine is 90-120 punctures per cm ² , the needle punch density on second needle-punched machine 80-100 punctures per cm ² .

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