CN102958689B - 用于制造柔性膜和其它制品的防水透气复合材料 - Google Patents

用于制造柔性膜和其它制品的防水透气复合材料 Download PDF

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CN102958689B
CN102958689B CN201180031205.0A CN201180031205A CN102958689B CN 102958689 B CN102958689 B CN 102958689B CN 201180031205 A CN201180031205 A CN 201180031205A CN 102958689 B CN102958689 B CN 102958689B
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fiber
woven composite
woven
composite
unidirectional
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CN102958689A (zh
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R·J·唐斯
C·M·亚当斯
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Dsm Protective Materials Co ltd
Evant Protective Materials Co ltd
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Cubic Tech Corp
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  • Textile Engineering (AREA)
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Abstract

一种防水透气材料，其相比于传统材料具有更高的强度重量比和更高的抗撕裂性重量比，且可以应用于广泛领域的潜在用途中。一种非织造复合材料包括至少一个防水透气（W/B）膜、具有被粘合剂包住的相互平行的多个纤维的第一单向非织造复合材料层、具有被粘合剂包住的相互平行的多个纤维的第二单向非织造复合材料层。所述第一单向非织造复合材料层设置成使得纤维相对于所述第二单向非织造复合材料层的纤维成90°取向，并在所述第一多个纤维和所述第二多个纤维之间形成间隔。在所述间隔中不存在粘合剂。

Description

用于制造柔性膜和其它制品的防水透气复合材料
相关申请的交叉引用
本申请是2010年6月24日提交的题为“WATERPROOFBREATHABLE COMPOSITE MATERIALS FOR FABRICATION OFFLEXIBLE MEMBRANES AND OTHER ARTICLES”的美国专利申请No.61/358,394的非临时申请，本申请还是2010年8月3日提交的题为“SYSTEM AND METHOD FOR COLOR TRANSFER TO LAMINATECOMPOSITE MATERIALS AND OTHER ARTICLES”的美国专利申请No.61/370,448的非临时申请，其均以引用的方式并入本文。
技术领域
本申请涉及防水透气材料，具体地，涉及用于各种用途和应用的改良的防水透气材料。
背景技术
在现有技术中，层压工序用于将防水透气（“W/B”）薄膜或膜（通常由PTFE或PU制造）粘合到织造织物。织造材料（通常是尼龙或聚酯）的目的在于提供材料性质，例如强度、对层压的抗拉伸性和抗撕裂性。所得W/B织造材料和随机取向的非织造W/B材料的问题在于：其重量重、低强度重量比，过厚和低抗撕裂性以及撕裂停止（rip stop）的性质限制了材料的使用。由此，存在可以应用于潜在用途的广泛的领域的具有更高强度重量比和更高抗撕裂性重量比（tearresistance-to-weight ratio）的材料的需要。
发明内容
一种防水透气材料，其相比于传统材料具有更高的强度重量比和更高的抗撕裂性重量比，并可以应用于广泛领域的潜在用途中。一种非织造复合材料包括至少一层防水透气（W/B）膜、具有被粘合剂包住的相互平行的多个纤维的第一单向非织造复合材料层、具有被粘合剂包住的相互平行的多个纤维的第二单向非织造复合材料层。该第一单向非织造复合材料层设置成使得纤维相对于第二单向非织造复合材料层的纤维成90°取向，并在第一多个纤维和第二多个纤维之间形成间隔。在间隔中不存在粘合剂。
附图说明
通过参考详细的说明书和权利要求书并结合附图可以获得对本发明的更全面的理解，在整个附图中相似的附图标记指代相似的要素，以及：
图1显示具有一个方向增强的构造的织造材料的示例性实施方案；和
图2显示具有两个方向增强的构造的织造材料的示例性实施方案；
图3显示具有四个方向增强的构造的织造材料的示例性实施方案；
图4显示具有四个方向增强的构造和偏置层片加强层和织物顶层的织造材料的示例性实施方案的分解图；
图5显示有非W/B聚合物涂布纤维并嵌入W/B聚合物的具有一个方向增强的构造的织造材料的示例性实施方案；
图6显示具有一个方向增强的构造的织造材料的示例性实施方案，其中非W/B聚合物涂布纤维并嵌入W/B聚合物，并且粘合到W/B膜；
图7显示有嵌入W/B聚合物的纤维的具有一个方向增强的构造的织造材料的示例性实施方案；
图8显示有嵌入W/B聚合物并粘合到W/B膜的纤维的具有一个方向增强的构造的织造材料的示例性实施方案；
图9显示有嵌入W/B聚合物的纤维的具有四个方向增强的构造的织造材料的示例性实施方案；以及
图10显示有嵌入W/B聚合物并粘合到W/B膜的纤维的具有四个方向增强的构造的织造材料的示例性实施方案。
具体实施方式
尽管本文中充分详细地描述示例性实施方案以使得本领域技术人员能够实施本发明，但应当理解，在不背离本发明的实质和范围的情况下，可以了解其它实施方案并可以做出合乎逻辑的材料、组件和机械改变。由此，仅出于说明的目的而提供如下详细的描述。
防水透气的复合材料提供下一代的重量轻、强度高、柔性的防水透气（“W/B”）材料。在一示例性实施方案中，将W/B膜（例如PTFE或尿烷W/B材料）结合到复合材料。如本文中所使用的，复合材料的定义是：一层或多层单向纤维和向一个或多个方向取向的聚合物基质层片。这些膜可以是防水且又多孔的，以使气体和水蒸气流动；或者其可以是非多孔的，但允许水蒸气经由扩散而移动穿过材料。在一示例性实施方案中，复合材料由稀疏散布的高强度纤维制得，该高强度纤维例如为 芳香族聚酰酩、聚酯、由粘合剂或其它材料涂布的其它材料、或其任何组合。该粘合剂或使用的其它聚合物可以是W/B型尿烷聚合物，但其它非尿烷W/B材料或非尿烷非W/B材料也可以是合适的。示例性的复合材料的优点在于：在不牺牲强度或其它材料性质的情况下，制造的材料能显著地更薄、更具柔性、具有更好的接触和触摸的特征，并且比织造材料和随机取向的非织造材料更轻。在一示例性实施方案中，W/B复合材料比市场上现有可得的其它柔性W/B材料具有更高的强度重量比和抗撕裂性。另外，示例性的复合材料对膜的透气性的影响有限，因为纤维长丝、单丝、线或丝束之间的部分没有阻隔气体渗透的聚合物，该部分或包括允许气体透气性同时防止或阻止液体流动的可渗透的W/B粘合剂或薄膜。丝束是多个单丝的纤维束。该W/B膜可以掺入或不掺入单向增强长丝、纤维或丝束。
在一示例性实施方案中，并参考图1，非织造层状复合材料100包括至少一层W/B膜101和至少另外一层单向非织造复合材料102。在一实施方案中，非织造复合材料102包括相互平行的多个纤维111。纤维111被形成盖的粘合剂112包住。另外，非织造复合材料102的纤维111布置成使得形成无粘合剂区域120的间隔。然而，也设想非织造层状复合材料的其它合适的构造。
在另一示例性实施方案中，并参考图2，非织造W/B复合材料200包括至少一层W/B膜层201、第一单向非织造复合材料202和第二单向非织造复合材料203。与非织造复合材料102相似，非织造复合材料202、203各自包括相互平行的多个纤维211。纤维211被形成盖的粘合剂212包住。另外，非织造复合材料202和非织造复合材料203取向成使得各自的纤维211相对于相邻的纤维211的层旋转90°。这种非织造W/B复合材料200的交叉影线的构造通过无粘合剂区域层形成间隔220。
在另一示例性实施方案中，并参考图3，非织造W/B复合材料30包括至少一层W/B膜层31、第一单向非织造复合材料302、第二单向非织造复合材料303和第三单向非织造复合材料304。与非织造复合材料102、202和203相似，非织造复合材料302、303、304各自包括相互平行的多个纤维311。纤维311被形成盖的粘合剂312包住。另外，非织造复合材料层302、303、304取向成使得各自的纤维311相对于相邻的纤维311的层旋转45°或90°。这种非织造W/B复合材料300的附加的交叉影线的构造通过无粘合剂区域层形成间隔320。如图3所示，由于纤维311的额外的重叠层和额外的偏置角度，该无粘合剂区域间隔320在非织造W/B复合材料300中比在非织造W/B复合材料200中更加紧凑。
另外，在一示例性实施方案中，通过将堆叠的层通过一套加热的夹辊、热压机、加热的真空压力机、加热的压带机或将堆叠的层放入真空层压工具并将堆叠物暴露于高温，使用压力和温度将材料层合并和固化在一起。另外，例如由蒸压机提供的外部压力也可以被用于提高施加在层上的压力。应用真空密封到层压工具的真空袋可以覆盖所述真空层压工具以提供压力。本领域技术人员已知的其它层压方法也可以是合适的。
用作高强度重量比阻挡层功能的W/B复合材料允许通过该材料的气体（包括水蒸气）传输，但不传输液体水。另外，在各种实施方案中，示例性的W/B复合材料可以用于但不限于：睡袋罩、帐篷壁和服装。在一实施方案中，例如单向纤维增强带的复合材料粘合到W/B膜。示例性材料的优选实施方案是包括在一表面上粘合到Cubic Tech产品CT1的eVent W/B膜的材料，由此产生Cubic Tech产品CTB1B3/NF。各种实施方案可以包括W/B膜、织造和非织造织物以及由Cubic Tech生产的其它材料的其它构造。
在第一个示例性实施方案中，将一层或多层W/B膜粘合到CubicTech层压材料的两个外表面。该层压材料可以是各种不同产品重量、强度、颜色和图案的层压材料。在第二个示例性实施方案中，所述复合材料包括通过使用颜料或染料升华对基质或膜着色。在第三个示例性实施方案中，使用阻燃粘合剂或聚合物，或者能够向易燃基质或膜添加阻燃剂以改善耐燃性。阻燃添加剂的实例包括：DOW D.E.R.593溴化树脂、Dow Corning 3阻燃树脂和有三氧化锑的聚氨基甲酸乙酯树脂（例如获自PDM Neptec ltd.的EMC-85/10A），但是其它阻燃添加剂也可以是合适的。为了改善耐燃性可以使用的阻燃添加剂包括FyrolFR-2、Fyrol HF-4、Fyrol PNX、Fyrol 6和SaFRon 7700，但是其它添加剂也可以是合适的。通过使用例如Nomex或Kevlar的阻燃纤维、使用陶瓷或金属线长丝、在纤维制造工序中将阻燃化合物直接添加到纤维配制物中或通过上胶（sizing）将酌情掺有以上所列或其它阻燃化合物的聚合物或粘合剂涂布纤维，也能将阻燃性和自灭火特性添加到所述纤维。使用于层压材料的任何织造或稀松布材料可以由供应商进行阻燃性预处理，或者在制造工序中用阻燃化合物涂布并浸渍。
在第四个示例性实施方案中，所述材料进一步包括混合成层层片或混合堆叠物以修改或改善所述材料的各种机械性质。混合层片（hybrid ply）定义为在组成复合材料的单层片内至少2（两）种非基质元件（各种纤维类型、线、网等）的使用。混合堆叠物定义为唯一分离的层片的使用，各个层片包括至少1（一）种不同于至少一个相邻层片的非基质元件。非基质元件，例如，可以是各种纤维类型、用金属或氧化物涂布或镀的纤维、线单丝、线网等。在第五个示例性实施方案中，W/B复合材料在一面或两面上包括织造或非织造布或皮革。在第六个示例性实施方案中，所述W/B复合材料在一面或两面上包括相容的粘合剂用于层压到第三方织物（织造、非织造、皮革），以升级强度、抗撕裂性（撕裂停止），并将W/B性质添加到第三方织物。在第七个实施方案中，通过在聚合物树脂、薄膜或织物上添加或涂布一种或多种抗微生物剂，并结合对用于复合材料的纤维、单丝、线或丝束进行抗微生物处理，进一步向所述W/B复合材料添加抗微生物/抗病原体抵抗力。典型的材料包括制造的OxiTitan Antimicrobial和纳米银化合物、巯氧吡啶钠、吡啶硫酮锌2-氟乙醇、1-溴-2-氟乙烷、苯并咪唑、氟罗沙星、1,4-丁二磺酸二钠盐、2-（2-吡啶基）异硫脲N-氧化物盐酸盐、季铵盐、2-巯基吡啶-1-氧化物、复方吡硫锌、复方吡啶硫酮铜、镁吡啶硫酮、双硫氧吡啶（BISPYRITHIONE）、羟基吡啶硫酮、α-溴肉桂-凝胶（α-Bromo Cinnam-Gel）、KFO ABC硅胶。纤维形式如线、丝束和单丝能够用银纳米粒子处理，或者可以经由化学镀或电镀、真空沉积或用包含银化合物的聚合物、粘合剂涂布、或通过上胶而施加银涂层。抗微生物/抗病原体材料也可以是合适的。
将传统W/B材料构造成或层压成基于织造的织物。相反地，在一示例性实施方案中，并参考附图4，W/B复合材料400可以包括至少一层粘合到第一膜层401和第二膜层406中至少一层的纤维402、403、404、405。纤维402、403、404、405可以是膜或织物层。层401、406可以是膜、织物层或层片增强层。在一些实施方案中，仅包括单膜或单织物层。在另一示例性实施方案中，W/B复合材料仅包括增强纤维层片，不包括一面或两面膜或织物层。在一示例性实施方案中，至少一层纤维是由单向纤维/基质带制造的柔性的非织造复合材料。另外，至少一种纤维可以包括单纤维层或多个纤维层。此外，该纤维层可相对于其它纤维层以任何取向。例如，图2显示了相对于膜层中的轴，取向为0°和90°的两层纤维。图3和图4显示了相对于膜层中的轴，取向为0°、90°、-45°和+45°的四层纤维的示例性实施方案。散布的纤维布置成使得纤维的长丝形成促进透气性和气体渗透性的“窗”。换言之，该长丝具有受控制的间隔，此间隔导致在每个纤维层的长丝之间有间隙，且每个纤维层的间隙与相邻的纤维层的纤维长丝间隙对齐以形成穿过孔（窗）。在一个实施方案中，在每个纤维层中的长丝间隔可以在约一微米到约一厘米的范围内。根据示例性实施方案，气体渗透长丝窗的尺寸至少与W/B膜中的孔一样大。该长丝窗与W/B膜中的孔允许传输气体或水蒸气通过该材料。换言之，示例性的复合材料在长丝之间产生“窗”的网格，转而产生半多孔材料。
包括单向纤维/基质带的W/B复合材料可以利用树脂或其它粘合剂将材料粘合到一起。根据示例性实施方案，柔性非织造复合材料包括受控制的粘合剂含量用于优化控制粘合剂。在使用非W/B粘合剂或W/B粘合剂的示例性实施方案中，柔性非织造复合材料的粘合剂含量足以将其粘附到其它层，但不足以形成连续层。换言之，在柔性非织造复合材料上的树脂粘合剂的量使其不覆盖在纤维层中的“窗”，而留出所需的间隙。应用于每个材料的受控制的粘合剂的量取决于该材料层的特征。一些材料相比其它材料需要更多的粘合剂以产生粘合。
在另一示例性实施方案中，W/B粘合剂用于粘合材料,该W/B粘合剂可以覆盖“窗”，同时保持材料的透气功能性。例如，图5提及非W/B聚合物501涂布长丝502且W/B聚合物503填充空的间隔或窗的实施方案。另外，在一个实施方案中，并参考图6，非W/B聚合物601涂布长丝602，W/B聚合物603填充空的间隔或窗，并将W/B膜604粘合到W/B聚合物603。图7显示具有嵌入W/B聚合物703的长丝702的实施方案。另外，图8提及具有嵌入W/B聚合物803，并还粘合到W/B膜804的长丝802的实施方案。在图5、6、7和8中提及的实施方案可以包括涂布纤维、W/B膜、织造织物或其它合适的材料的其它层。图9和图10是包括多层的这样的实施方案的实例。
在一示例性实施方案中，并参考图9，多向增强的W/B材料900包括嵌入W/B聚合物903的纤维902。纤维902和W/B聚合物903的多层以相对于膜层中的轴的0°、90°、+45°和-45°的设计取向加以堆叠。另外，图10提及包括嵌入W/B聚合物1003并也粘合到W/B膜1004的纤维1002的多向增强的W/B材料1000的实施方案。与多向增强的W/B材料900相似，多向增强的W/B材料1000包括以相对于膜层中的轴的0°、90°、+45°和-45°的设计取向堆叠的纤维902和W/B聚合物903的多层。合适的W/B粘合剂的一个实例是热塑性聚氨酯（TPU），但其它材料也是合适的。
关于材料、过程、方法和制造的其它细节，参考1995年11月28日授权的题为“COMPOSITE MATERIAL FOR FABRICATION OFSAILS AND OTHER ARTICLES”的美国专利No.5,470,632以及1994年8月2日授权的题为“MATERIAL FOR THE FABRICATION OF SAILS”的美国专利No.5,333,568，其内容以引用的方式并入本文用于其全文的任何目的。
上文通过具体的实施方案已经描述了益处、其它优点和问题的解决方案。然而，益处、优点和问题的解决方案以及任何可能带来任何益处、优点或产生解决方案或使其变得更加明显的要素不被解释为任何或全部权利要求的重要的、必需的或必要的特征或要素。本说明书中所使用的术语“包括”、“包含”或其任何其他变体旨在覆盖非排他性的包含，使得包括一系列要素的过程、方法、制品或装置不但包括这些要素，而且可以包括其它没有清楚列出的要素，或者可以包括这些过程、方法、制品或装置固有的要素。另外，除非清楚地描述为“必要的”或“重要的”，否则不需要本文所述的要素用于实施本发明。

Claims (10)

1.一种非织造复合材料，其包括：
至少一层防水透气膜；和
第一单向非织造复合材料层，其包括相互平行的第一多个纤维，其中所述第一多个纤维被非防水透气粘合剂包住；
其中平行布置所述第一单向非织造复合材料层的所述第一多个纤维，使得在所述第一多个纤维之间形成间隔，其中所述间隔用防水透气聚合物填充。
2.根据权利要求1所述的非织造复合材料，其进一步包括：
第二单向非织造复合材料层，其包括相互平行的第二多个纤维，其中所述第二多个纤维被非防水透气粘合剂包住；
其中所述第一单向非织造复合材料层设置成使得所述第一多个纤维相对于所述第二单向非织造复合材料层的所述第二多个纤维成90°取向。
3.根据权利要求2所述的非织造复合材料，其进一步包括：
第三单向非织造复合材料层，其包括相互平行的第三多个纤维，其中所述第三多个纤维被非防水透气粘合剂包住；
其中所述第三单向非织造复合材料层设置成使得所述第三多个纤维相对于所述第二单向非织造复合材料层的所述第二多个纤维成45°取向。
4.根据权利要求3所述的非织造复合材料，其进一步包括粘合到所述第三单向非织造复合材料层的第二防水透气膜。
5.根据权利要求1所述的非织造复合材料，其中在所述第一多个纤维的每个纤维之间的所述间隔在1微米到1厘米的范围内。
6.根据权利要求1所述的非织造复合材料，其中在所述第一多个纤维的每个纤维之间的所述间隔至少与至少一层的防水透气膜中的孔一样大。
7.根据权利要求1所述的非织造复合材料，其中所述非织造复合材料使用在睡袋罩、帐篷或服装中的至少一种中。
8.根据权利要求1所述的非织造复合材料，其进一步包括阻燃聚合物层。
9.根据权利要求1所述的非织造复合材料，其进一步包括涂布在所述第一多个纤维上的抗微生物剂。
10.根据权利要求1所述的非织造复合材料，其进一步包括在防水透气聚合物中的抗微生物剂。
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EP2585290A4 (en) 2015-01-28
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US8784968B2 (en) 2014-07-22
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US9358755B2 (en) 2016-06-07
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US20160339671A1 (en) 2016-11-24
US20120100334A1 (en) 2012-04-26
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