TW201525253A - Method for providing a carrier material - Google Patents

Abstract

A method is provided to manufacture a carrier material comprising a nonwoven layer of fibers and threads extending in the longitudinal direction of the carrier material comprising the steps of supplying a nonwoven layer of fibers, supplying a scrim comprising weft threads comprising a polymer having a melting temperature equal to or less than the lowest melting temperature of the thermoplastic fibers comprised in the nonwoven layer of fibers and thermally bonding the scrim to the nonwoven layer of fibers.

Description

Method of providing a carrier material

The present invention relates to a method of providing a carrier material, wherein the carrier material comprises a nonwoven fibrous layer and a yarn extending in the longitudinal direction of the carrier material.

Carrier materials comprising nonwoven layers are used in many applications such as, for example, asphalt roofing films, roofing lining sheets, and (buffered) vinyl floor coverings.

The high temperatures and/or high tensions encountered in the manufacturing process may require the addition of yarns, particularly high modulus yarns such as, for example, glass yarns, in the longitudinal direction of the carrier material to withstand during processing, particularly at elevated temperatures. High tension in the machine direction. Such carriers are known, for example, from EP 1 372 951, and usually by introducing some individual yarns directly into the nonwoven fibrous layer during formation of the nonwoven fibrous layer, preferably at regular intervals; or by Each of the yarns is laminated to a pre-manufactured nonwoven fabric layer.

EP 0 239 207 A2 discloses a method of making a paper felt using a low-melting gauze of needle-punched batting followed by heat treatment.

However, the introduction of a large number of individual yarns is a rather complicated method that requires large creels to unwinding from the bobbins. Individual yarns. When the individual yarns are directly introduced into the nonwoven fabric layer during the formation of the nonwoven fabric layer, the manufacturing efficiency may be due to the formation of the nonwoven fabric layer and the introduction of the respective yarns. Broken and negatively affected.

Furthermore, in order to ensure that the individual yarns extending in the longitudinal direction are kept at regular intervals, it is necessary to control the tension on each of the individual yarns to the same level, thus causing during the unwinding of the individual yarns. There is a high demand for process control.

Accordingly, there is a need for an improved method of providing a carrier material comprising a nonwoven fibrous layer and a yarn extending in the longitudinal direction of the carrier material.

It is an object of the present invention to provide an improved method of making a carrier material wherein the carrier material comprises a nonwoven fibrous layer and a yarn extending in the longitudinal direction of the carrier material.

The object of the present invention is achieved by a method of producing a carrier material as claimed in claim 1.

Thermally bonding a gauze to a nonwoven fibrous layer is capable of stabilizing the distance between the yarns extending longitudinally of the carrier material in an efficient manner, wherein the gauze comprises a weft thread comprising a melting temperature equal to or lower A polymer comprising the lowest melting temperature of the fibers in the nonwoven layer.

As is well known to those skilled in the art, a gauze is an open lattice structure of at least two sets of parallel yarns, wherein the first set of parallel yarns are oriented at an angle to the second set of parallel yarns. Degree, usually at an angle of 90°. The first set of parallel yarns may be joined to the second set of parallel yarns by chemical bonds, and/or the first set of parallel yarns may be interwoven with the second set of parallel yarns to form a woven scrim. Preferably, the opening in the gauze has at least one dimension in the plane of the carrier material which is at least 1 mm, preferably at least 2 mm, more preferably at least 5 mm. More preferably, the opening in the gauze has two dimensions in the plane of the carrier material, which is at least 1 mm, preferably at least 2 mm, more preferably at least 5 mm.

The carrier material is understood to be substantially a two-dimensional structure having an amount that is less than at least one order of thickness and length of the carrier material, preferably at least two orders, more preferably at least three. The amount of the series.

Although a carrier material comprising a non-woven layer and a gauze composed of both glass and warp yarns can solve some problems in the process of receiving high tension and/or high temperature of the carrier material, Presenting the glass yarn as a weft in the gauze can induce surface irregularities in the final product such as, for example, (buffered) vinyl floor coverings, roof lining sheets or asphalt roofing films.

When the nonwoven fabric layer is shrunk or shrunk in the cross machine direction at a high temperature, particularly when exposed to a high tension in the machine direction, the glass yarn contained as a weft in the gauze may be flexed due to compressive stress, ie , the weft is curved or kinked.

In a specific example, the weft of the gauze is configured such that after the gauze is thermally bonded to the nonwoven layer, the individual wefts are still present in a continuous phase but have no hardness to cause surface defects, such as, for example, in Printing errors and/or surface irregularities during the manufacture of the (buffered) vinyl floor covering may cause surface irregularities during the manufacture of the asphalt film or roof lining sheet.

In one embodiment, the weft of the gauze is completely melted during the thermal bonding of the gauze to the nonwoven fibrous layer such that the weft does not exhibit a continuous phase after thermal bonding. Since the weft does not remain in the gauze after heat bonding to the nonwoven layer, this prevents surface defects from forming, such as, for example, printing errors and/or surface defects during the manufacture of the (buffered) vinyl floor covering. Regularity, or surface irregularities formed during the manufacture of asphalt film or roofing lining sheets.

In one embodiment, the gauze is thermally bonded to the preformed nonwoven fibrous layer, i.e., it is consolidated by any suitable consolidation technique, such as by, for example, calendering the fibrous web between two calender rolls ( Web of fibers), by mechanical needling, by water entanglement, by ultrasonic bonding, by thermal bonding or by any combination thereof.

In a specific example, the gauze is directly thermally bonded to the non-woven fiber layer after the unconsolidated nonwoven fiber layer is formed, to simultaneously achieve the consolidation of the nonwoven fiber layer and thermally bonding the gauze to the non-woven fabric. Fiber layer. In this particular example, an individual nonwoven fiber layer consolidation step is not required, thus achieving a more efficient manufacturing process.

The nonwoven fibrous layer can comprise thermoplastic polymer fibers to provide sufficient tear strength and/or elongation at break for the carrier material.

In a specific example, the weft of the gauze is mainly made of a polymer having a melting temperature equal to or lower than the lowest melting temperature of the fibers contained in the nonwoven fabric layer. Preferably, the weft of the gauze is made of a polymer having a melting temperature lower than a minimum melting temperature of the thermoplastic fiber polymer contained in the nonwoven fiber layer by at least 10 ° C, preferably at least 20 ° C, more preferably Good for at least 50 ° C. The term "prepared primarily from" is understood to mean that the weft thread constitutes the total weight of the weft polymer having a melting temperature equal to or lower than the lowest melting temperature of the fibers contained in the nonwoven layer. It is at least 60% by weight, preferably at least 75% by weight, more preferably at least 90% by weight, still more preferably at least 95% by weight, even more preferably at least 99% by weight, most preferably 100% by weight.

The melting temperature of the thermoplastic polymer is determined by a differential scanning calorimeter (DSC), such as the temperature at the maximum of the endothermic melting peak after heating the polymer at a rate of 20 ° C/min.

In a specific example, the yarn extending in the longitudinal direction of the carrier material comprises a high modulus yarn such as, for example, a polyester yarn such as a polyethylene terephthalate (PET) yarn; a polyamide yarn Wires, such as polyamide-6 (PA6) yarns; glass yarns, aromatic polyamide yarns or carbon yarns and/or other high modulus yarns or any combination thereof, which are resistant to, for example, asphalt roofs High temperatures and/or high tensions encountered in the manufacture of films, roof lining sheets and (buffered) vinyl floor coverings. The high modulus yarn may have a modulus of at least 1 GPa, preferably at least 5 GPa, preferably at least 10 GPa, preferably at least 15 GPa, preferably at least 20 GPa. It is preferably at least 25 GPa, preferably at least 40 GPa, more preferably at least 50 GPa, most preferably at least 75 GPa. Preferably, the high modulus yarn extending in the longitudinal direction comprises glass yarn. Preferably, all of the high modulus yarns extending in the longitudinal direction of the carrier are high modulus yarns, and more preferably all of the high modulus yarns are glass yarns.

The type and amount of high modulus yarn included as a high modulus yarn extending in the longitudinal direction of the carrier is selected such that the modulus of the carrier is at least 25 Newtons/5 centimeters, as per EN29073-3 ( 08-1992) decided to use a clamp speed of 200 mm/min and a load at 2% of the specified elongation (LASE 2%). Preferably, the carrier has a modulus of at least 50 Newtons/5 cm, more preferably at least 100 Newtons/5 cm, even more preferably at least 200 Newtons/5 cm, and most preferably at least 250 Newtons/5 cm.

Within the scope of the present invention, it is to be understood that the term "fiber" is used to mean both staple fibers and filaments. The staple fiber has fibers of a relatively short length specified in the range of 2 to 200 mm. The filaments have fibers having a length greater than 200 mm, preferably greater than 500 mm, more preferably greater than 1000 mm. The filaments may even be continuously continuous, such as when the filaments are formed by continuous extrusion and by spinning through a spinning orifice in a spinneret.

The fibers can have any cross-sectional shape, including circular, trilobal, multilobal or rectangular, the latter having a width and height, wherein the width can be much greater than the height so that the fibers are a ribbon in this particular embodiment. Further, the fibers can be one-component, two-component or even multi-component fibers.

In one embodiment, the fibers in the nonwoven layer have fibers having a linear density in the range of 1 to 25 dtex, preferably in the range of 2 to 20 minutes, more preferably In the range of 5 to 15 cents, preferably in the range of 5 to 10 cents, to provide processing stability and quality regularity to the carrier while maintaining sufficient structural openness for high viscosity materials such as For example, asphalt or PVC plastisol penetrates through the carrier. The unit "Texas" defines the fiber fineness, such as its weight per 10,000 meters, in grams.

The nonwoven fibrous layer contained in the carrier may be any type of nonwoven fabric such as, for example, staple fiber nonwoven fabric manufactured by a well-known method, such as a carding method, a wet-laid method or a woven fabric layer ( Air-laid) method or any combination thereof. The nonwoven fabric layer may also be a non-woven fabric composed of filaments produced by a well-known spunbonding method, wherein the filaments are extruded from a spun nozzle and subsequently laid on a conveyor belt such as a long screen. And subsequently bonding the web to form a nonwoven fibrous layer; or by a two-step process wherein the filament is spun and wound onto a bobbin, preferably in the form of a multifilament yarn, followed by unwinding the roll The step of winding the multifilament yarn, and laying the filament on a conveyor belt such as a long screen, and bonding the web to form a nonwoven fabric layer.

Preferably, the fiber-based filaments in the nonwoven fibrous layer provide for the carrier and/or the final infiltrated product such as, for example, an asphalt roofing film, a roofing lining sheet or a (buffered) vinyl floor covering. High tensile strength and/or high tear strength.

The nonwoven fibrous layer may be composed of thermoplastic fibers having at least 50% by weight of the total weight of the fibers in the nonwoven fibrous layer, preferably to It is 75% by weight, more preferably at least 90% by weight, even more preferably at least 95% by weight. Increasing the amount of thermoplastic fibers in the nonwoven layer, increasing tensile strength and/or tear resistance and increasing the softness of the final infiltrated product.

In one embodiment, the nonwoven fibrous layer is comprised of 100% by weight of thermoplastic fibers of the total weight of the fibers in the nonwoven fibrous layer.

The thermoplastic polymer constituting the thermoplastic fibers in the nonwoven fabric layer can be of any type resistant to high temperatures such as, for example, in the production of asphalt roofing films, roofing lining sheets, and (buffered) vinyl floor coverings. Thermoplastic polymer. The thermoplastic fibers in the nonwoven fibrous layer may comprise a polyester such as, for example, polyethylene terephthalate (PET) (based on either DMT or PTA), polybutyl phthalate (PBT), polypairs Propylene citrate (PTT), polyethylene naphthalate (PEN) and/or polylactic acid (PLA); polyamines such as, for example, polyamido-6 (PA6), polyamido-6,6 ( PA6,6) and/or polyamine-6,10(PA6,10); polyphenylene sulfide (PPS), polyethylideneimine (PEI) and/or polyoxymethylene (POM) and/or Any copolymer or any blend thereof.

The thermoplastic fibers may comprise up to 25% by weight of additives based on the total weight of the fibers, such as, for example, textile aids, fillers, flame retardant materials, UV inhibitors, crystal retarders/accelerators, plasticizers, heat Stabilizers, antimicrobial additives, colorants such as, for example, carbon black, or any combination thereof.

The weight of the nonwoven fibrous layer contained in the carrier may range from 40 g/m 2 to 250 g/m 2 , preferably from 45 g/m 2 to 200 g/m 2 . Preferably in the range 50 克 / m ^ 2 to 150 g / m ^ 2 , more preferably in the range of 50 g / m ^ 2 to 120 g / m ^ 2 , the best in the range of 60 g / m ^ 2 to 100 g / square Within the metric, the structure of the carrier is kept sufficiently open to penetrate from the infiltrating material, such as, for example, asphalt or PVC plastisol, and to provide sufficient mechanical adhesion of the infiltrating material to the carrier material. A lower nonwoven fiber layer weight results in less infiltration of materials such as asphalt or PVC plastisol, but too low a nonwoven fiber layer weight may cause PVC plastisol (or bitumen) in the PVC that has been gelled into a bonded PVC. The material exits through the carrier before it.

In one embodiment, the nonwoven fibrous layer is preferably comprised of filaments which may be comprised of a single type of monocomponent fiber which is bonded by any suitable bonding technique, such as, for example, by two calender rolls. The fiber web is calendered, by mechanical needling, by water entanglement, by ultrasonic bonding or by any combination thereof.

In another embodiment, the nonwoven fibrous layer is preferably comprised of filaments, which may comprise two types of monocomponent fibers, each type of monocomponent fiber being polymerized by different chemical structures having different melting points. Composition. Preferably, the two different polymers have a melting point difference of at least 10 ° C, preferably at least 20 ° C. More preferably, the difference in melting point is at least 50 °C. This product can be thermally bonded by subjecting the fibrous web to a temperature within the melting point of the polymer having a lower melting point.

In still another embodiment, the nonwoven fibrous layer is preferably comprised of filaments, which may comprise bicomponent fibers. The bicomponent fiber is a fiber composed of two polymers of different chemical architectures. The following is a description of the basic differences between the three types of bicomponent fibers: side-by-side, core-sheath And island-type bicomponent fibers. In one embodiment, the difference in melting point of the two polymers constructing the bicomponent fiber is at least 10 ° C, preferably at least 20 ° C. More preferably, the difference in melting point is at least 50 °C. The nonwoven layer comprising bicomponent fibers, when composed of side-by-side and/or core-sheath bicomponent fibers, allows the fiber web to be exposed to temperatures within the melting point of the polymer having a lower melting point Perform thermal bonding. In a preferred embodiment, the nonwoven carrier is primarily made from a core-sheath bicomponent fiber, preferably a filament. It is mainly understood that it means that at least 50% of the fibers contained in the nonwoven layer are core-sheath bicomponent fibers, preferably at least 75%, more preferably at least 90%, or even more Good is at least 95%, best at 100%.

Preferably, the core/sheath ratio in the core/sheath bicomponent fibers is between 95/5 vol% and 5/95 vol%. More preferably, the core/sheath ratio is between 50/50 vol% and 95/5 vol%.

In one embodiment, the sheath of the core/sheath bicomponent fiber consists essentially of polyamidoamine, preferably polyamido-6 (PA6), and the core consists essentially of polyester, preferably polypyrene Ethylene glycol (PET).

The carrier material may comprise one or more further layers, each layer being selected from the group of nonwoven fibers and/or gauze, for example to improve the quality uniformity of the carrier and/or to further reduce the nonwoven fibers contained in the carrier. The layers shrink and/or shrink in the cross machine direction.

Claims (11)

A method of providing a two-dimensional carrier material, wherein the carrier material comprises a nonwoven fibrous layer and a yarn extending in a longitudinal direction of the carrier material, wherein the method comprises the steps of: supplying a nonwoven layer; supplying one comprises a gauze adjacent to the coficial layer and coplanar warp and weft, and thermally bonding the gauze to the nonwoven fabric layer, wherein the gauze comprises a weft thread having a melting temperature equal to or lower than the inclusion The lowest melting temperature of the fibers in the nonwoven layer and the polymer below the melting temperature of at least a portion of the warp contained in the gauze. The method of claim 1, wherein the weft of the gauze is completely melted during the thermal bonding of the gauze to the nonwoven layer, such that the weft does not exhibit a continuous phase after thermal bonding. The method of any one of claims 1 to 2, wherein the gauze is thermally bonded to a prefabricated nonwoven layer. The method of any one of claims 1 to 2, wherein the gauze is directly thermally bonded to the nonwoven fibrous layer after the unconsolidated nonwoven fibrous layer is formed to achieve simultaneous consolidation of the nonwoven fibrous layer and The gauze is thermally bonded to the nonwoven layer. The method of any of the preceding claims, wherein the nonwoven layer comprises thermoplastic polymer fibers. A method according to any of the preceding claims, wherein the nonwoven layer comprises two types of monocomponent fibers, each type of monocomponent fiber being composed of a polymer having a different chemical structure with different melting points. The method of claim 6, wherein the polymers of the two types of monocomponent fibers have a melting point difference of at least 10 ° C, preferably at least 20 ° C, more preferably at least 50 ° C. The method of any one of claims 1 to 5, wherein the nonwoven fibrous layer comprises bicomponent fibers composed of two polymers having different chemical structures having different melting points. The method of claim 8, wherein the polymer of the two components of the bicomponent fiber has a melting point difference of at least 10 ° C, preferably at least 20 ° C, more preferably at least 50 ° C. The method of any of the preceding claims, wherein the yarn extending in the longitudinal direction of the carrier material comprises a high modulus yarn having a modulus of at least 1 GPa, preferably at least 5 GPa, preferably at least 10 GPa. Preferably, it is at least 15 GPa, preferably at least 20 GPa, more preferably at least 25 GPa, preferably at least 40 GPa, more preferably at least 50 GPa, most preferably at least 75 GPa. The method of claim 10, wherein the type and amount of the high modulus yarn are selected such that the modulus of the carrier is at least 25 Newtons/5 cm, preferably at least 50 Newtons/5 cm, more preferably at least 100. Newton/5 cm, even better, at least 200 Newtons/5 cm, optimally at least 250 Newtons/5 cm, according to EN29073-3 (08-1992), using a clamping speed of 200 mm/min, at 2% specific The load under the specified elongation (LASE2%) is determined.