CN106660303A - 用于乙烯基地板覆盖物的载体材料 - Google Patents
用于乙烯基地板覆盖物的载体材料 Download PDFInfo
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- 239000012876 carrier material Substances 0.000 title claims abstract description 68
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 title claims abstract description 39
- 229920002554 vinyl polymer Polymers 0.000 title claims abstract description 39
- 239000000835 fiber Substances 0.000 claims abstract description 155
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- 239000003292 glue Substances 0.000 claims description 5
- 239000011230 binding agent Substances 0.000 claims description 4
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- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 3
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Abstract
本申请提供了一种用于乙烯地面覆盖物的载体材料,其中所述载体材料包括含有至少50重量%的热塑性纤维的非织造层和用于消除乙烯地面覆盖物中的皱褶的稀松布。稀松布包含具有28特克斯或更小的线密度的纬纱。载体材料防止在乙烯基地板覆盖物中形成表面不规则和印刷错误。
Description
说明书:
本发明涉及载体材料,其包括包含热塑性纤维的非织造层,所述载体材料待被热塑性基体(例如沥青或PVC)浸渍,以制备最终的复合产品,例如屋顶,地板或地毯复合产品。本发明还涉及复合产品,例如衬垫的乙烯基地板覆盖物或其它地板,屋顶或地毯复合产品,其包含所述载体材料和浸渍到所述载体材料中的热塑性基质。
作为这种复合产品的实例,通过在载体材料上施加若干基于PVC的层来制备衬垫的乙烯基地板覆盖物,每个PVC层具有其自身的功能。
载体材料用一层PVC增塑溶胶浸渍,该PVC增塑溶胶在升高的温度下胶凝,通常在140℃至170℃的范围内,例如当浸渍的载体材料与热(金属)滚筒表面接触时胶凝。随后,将包含发泡剂的PVC增塑溶胶的发泡层涂布在胶凝的浸渍层上,其随后在升高的温度下也胶凝。
使用印刷单元将期望的油墨图案施加到胶凝的发泡层上。在该印刷层的顶部,施加澄清透明的PVC增塑溶胶层作为耐磨层,所述耐磨层在升高的温度下也胶凝。在底侧,通常施加包含相对大量发泡剂的可发泡PVC增塑溶胶的背衬层。发泡层和背衬层的PVC增塑溶胶中的发泡剂在固化步骤中在高于胶凝温度的温度(通常在170℃-230℃范围内)下活化,以发泡并固化发泡层中的PVC和背衬层中的PVC,以获得衬垫的乙烯基地板覆盖物。
包括由热塑性纤维构成的非织造载体的衬垫的乙烯基地板覆盖物是例如由FR2013722 A1和WO2005/118947 A1已知的。与非热塑性纤维基载体相比,这种由热塑性纤维构成的非织造载体为衬垫的乙烯基地板覆盖物提供了更好的抗撕裂性和柔性。
FR2013722 A1公开了可用作地板覆盖物的由具有氯乙烯涂层的尼龙(聚酰胺)长丝制成的非织造垫。非织造垫在长丝的交叉点通过氢键结合。
WO2005/118947 A1公开了非织造载体,其中非织造物由不同的聚合物制成,并且非织造载体通过源自包含在非织造载体中的长丝的聚合物热结合。
WO 01/09421 A2公开了用于屋顶油毡,墙壁和地板覆盖物的载体,其包含用粘结剂预固结的玻璃短切纤维非织造物和合成纤维的非织造物,它们通过水刺法结合在一起。载体可以包括稀松布(scrim)形式的增强件,其中线为约20至150特克斯。
然而,已经观察到,包含由热塑性纤维构成的非织造载体的衬垫的乙烯基地板覆盖物在衬垫的乙烯基地板覆盖物制造方法的加工中可能表现出褶皱,由于非织造载体在横向上的收缩和/或紧缩,褶皱基本上在衬垫的乙烯基地板覆盖物的纵向上延伸,取决于褶皱的数量和大小,这样得到低质量的衬垫的乙烯基地板覆盖物或甚至废品(即废料)中。
已发现,用于衬垫的乙烯基地板覆盖物的载体减少或甚至完全消除在衬垫的乙烯基地板覆盖物中在纵向上延伸的褶皱的形成,所述载体包括包含热塑性纤维的纤维的非织造层,和由线密度为34特克斯或68特克斯的通常可获得的玻璃纱作为经纱和纬纱构成的稀松布。单位特克斯将纤维的细度定义为以克计的它们的重量/1000米长度。
然而,已经观察到,由34特克斯或68特克斯的通常可获得的玻璃纱构成的这种稀松布可能在最终衬垫的乙烯基地板覆盖物中引起表面不规则和/或可能在施加至胶凝的发泡层上的期望的油墨图案中导致印刷错误。虽然不受理论的束缚,但据信在衬垫的乙烯基地板覆盖物中的表面不规则和/或印刷错误的产生是由稀松布的纬纱的屈曲引起的,即,当纤维的非织造层在横向上收缩或紧缩时由压缩应力引起的纬纱的弯曲或扭结。
仍然需要一种包括包含热塑性纤维的非织造层的载体材料,所述载体材料消除或至少减少现有技术载体材料中存在的问题。
本发明的一个目的是提供一种用于衬垫的乙烯基地板覆盖物的载体材料,其包括包含热塑性纤维的非织造层,其防止在衬垫的乙烯基地板覆盖物中形成褶皱,并且防止在衬垫的乙烯基地板覆盖物中产生表面不规则和/或印刷错误。
本发明的目的通过根据权利要求1所述的载体材料实现。
尽管与具有较高线密度的纱相比,预期具有较低线密度的纱具有较小的刚性,并且因此预期其具有较小的抗压缩应力性,但令人惊讶地发现,包括一个或多个纤维的非织造层的载体材料(其中每个纤维的非织造层由热塑性纤维构成各纤维的非织造层中的纤维总重量的至少50重量%,稀松布包含线密度为28特克斯或更小的玻璃纬纱,或线密度为50特克斯或更小的高模量聚酯纬纱)在衬垫的乙烯基地板覆盖物中防止或至少显著减少印刷错误和/或表面不规则的形成。
在一个实施方案中,稀松布包括高模量纬纱,例如玻璃纱或高模量聚酯纱。稀松布中的所有纬纱都可以是高模量纱。优选地,纬纱为无机纱,更优选线密度为28特克斯或更小,更优选20特克斯或更小,甚至更优选15特克斯或更小的玻璃纱。可选地,纬纱为有机纱,更优选线密度为50特克斯或更小,更优选40特克斯或更小,甚至更优选30特克斯或更小的高模量聚酯纱。
高模量纬纱优选具有至少25GPa,优选至少40GPa,更优选至少50GPa,最优选至少75GPa的模量。
单位特克斯将纤维、线、纱的细度定义为以克计的它们的重量/1000米长度。为了清楚起见,线或“纱”由大量长丝或纤维的组件制成,所述长丝或纤维各自具有比所述纱低得多的特克斯值。
根据定义,如本领域技术人员所熟知的,纬纱在横向上延伸,而经纱在纵向上延伸。
在一个实施方案中,只要复合产品制造过程中的张力被同时施加到载体材料的所有层,载体材料的一个(或更多个)纤维的非织造层和稀松布可以在最终复合产品(例如衬垫的乙烯基地板覆盖物)制造过程中作为两个(或更多个)分离的层提供,即彼此不连接,优选取向的平面彼此平行,更优选彼此直接相邻,即,彼此直接接触。
载体材料可以包括一个或多个另外的材料层,每个另外的材料层包括纤维的非织造层,其中纤维的非织造层包含占纤维的非织造层中的纤维总重量的至少50重量%的热塑性纤维,或稀松布,例如以改善载体材料的质量均匀性,以进一步减少包含在载体中的纤维的非织造层的横向上的收缩和/或紧缩。
对用于复合产品(例如衬垫的乙烯基地板覆盖物)的载体材料的一般要求是足够的表面规则性,即在载体材料的表面上足够均匀的厚度,这是在载体材料的整个宽度上规则地施加浸渍层所必需的。此外,需要足够的结构开放性,以使热塑性基质均匀地穿透载体材料,以使增塑溶胶与载体材料具有足够的粘附性,并且使得顶层和发泡的背衬层之间具有足够的层离强度。另一方面,载体材料应该表现出足够致密的表面,即,由纤维充分覆盖,以防止热塑性基体穿过载体材料掉落。
优选地,纤维的非织造层和稀松布以及任选的另外的材料层作为单一的整体载体材料提供,其中稀松布和纤维的非织造层(和任选的另外的材料层)彼此连接以形成一体化的载体材料。稀松布和纤维的非织造层彼此连接可以通过任何已知的合适的方法,例如通过使用粘合剂(如胶水和/或热熔胶),或通过热结合(如热风粘结或压延),和/或通过机械结合工艺(如缝合,机械针刺和/或流体缠结,例如水刺法)进行。术语“连接至”应理解为还包括其中稀松布位于两个纤维的非织造层之间(嵌入)的情况,其中纤维的非织造层经由任何合适的方法通过所述稀松布中的开口彼此结合,从而通过彼此结合的两个纤维的非织造层的纤维的包封,将稀松布的经纱和纬纱一体化至载体材料中。
在一个实施方案中,包含在载体材料中的稀松布包括在纵向上延伸的高模量经纱,例如玻璃纱或高模量聚酯纱。优选地,稀松布包括作为经纱的玻璃纱。优选地,稀松布中的所有经纱是高模量纱,更优选地,稀松布中的所有经纱是玻璃纱。高模量经纱优选具有至少25GPa,优选至少40GPa,更优选至少50GPa,最优选至少75GPa的模量,以减少纤维的非织造层在横向上的紧缩。
优选地,稀松布在纵向上的模量为至少20N/5cm,其可以通过选择包含在稀松布中作为经纱的高模量纱的类型和量来达到。模量根据EN29073-3(08-1992),在20℃的温度下以200mm/min的夹具速度作为在2%的指定伸长率(LASE2%)下的载荷而测定。优选地,稀松布在纵向上的模量为至少25N/5cm,更优选至少30N/5cm。
优选地,稀松布在纵向上的断裂强度为至少50N/5cm,更优选至少60N/5cm。
只要在制造衬垫的乙烯基地板覆盖物期间施加到载体材料上的张力不是太高,稀松布的经纱的线密度就可以在宽范围内变化,因为经纱在衬垫的乙烯基地板覆盖物中通常不可见。优选地,经纱的线密度为100特克斯或更小,更优选为50特克斯或更小,更优选为28特克斯或更小,甚至更优选为20特克斯或更小,最优选为15特克斯或更小,以便即使在稀松布制造期间施加非常高的张力的情况下也防止经纱在衬垫的乙烯基地板覆盖物中可见,并得到更平衡的稀松布结构。
优选地,稀松布以20至400个经纱每米宽度的量包含经纱,更优选25至300个经纱每米宽度的量,甚至更优选50至200个经纱每米宽度的量,最优选75至150个经纱每米宽度的量,以防止在衬垫的乙烯基地板覆盖物中形成褶皱。当相邻经纱之间的距离增加时,形成在纵向上延伸的褶皱的风险增加。优选地,经纱彼此间隔规则的距离。
经纱可以包括玻璃纱。玻璃纱可以包括任何类型的玻璃(E,C,S,R或AR(耐碱性))。特别地,AR-或E-玻璃由于其机械强度而是优选的。
在一个实施方案中,稀松布包括高模量纬纱,例如玻璃纱或高模量聚酯纱。稀松布中的所有纬纱都可以是高模量纱。优选地,纬纱是无机纱,更优选地是玻璃纱。高模量纬纱优选具有至少25GPa,优选至少40GPa,更优选至少50GPa,最优选至少75GPa的模量。
优选地,稀松布在横向上的模量为至少20N/5cm,其可以通过选择包含在稀松布中作为经纱的高模量纱的类型和量来达到。优选地,稀松布横向上的模量为至少25N/5cm,更优选至少30N/5cm。
优选地,稀松布在横向上的断裂强度为至少30N/5cm,更优选至少40N/5cm。
优选地,稀松布以10至400个纬纱每米长度的量包含纬纱,更优选15至300个纬纱每米长度的量,甚至更优选20至200个纬纱每米长度的量,最优选25至100个纬纱每米长度的量。优选地,纬纱彼此间隔规则的距离。
纬纱可以包括玻璃纱。玻璃纱可以包括任何类型的玻璃(E,C,S,R或AR(耐碱性))。特别地,AR-或E-玻璃由于其机械强度而是优选的。
玻璃纱可以包括胶料以改善纱线的处理。可选地或附加地,玻璃纱也可涂布有聚合物涂层,如SBR弹性体或丙烯酸类聚合物。
在横向上延伸的稀松布的纬纱,特别是玻璃纬纱可以是单个长丝,也称为单丝,具有28特克斯或更小,优选20特克斯或更小,更优选15特克斯或更小的线密度。单丝可以具有任何横截面形状,包括圆形,三叶形,多叶形或矩形,所述矩形表现出宽度和高度,其中宽度可以显著大于高度,即宽度与高度之比为至少2,优选至少5,更优选至少10,最优选至少25,从而使得该实施方案中的单丝为带。优选地,单丝具有圆形横截面形状。
可选地,在横向上延伸的稀松布的纬纱可以包括包含多个单独的细长丝的复丝纱,总复丝纱具有28特克斯或更小,优选20特克斯或更小,更优选15特克斯或更小的线密度。复丝纱的单个细长丝可以具有任何横截面形状,包括圆形,三叶形,多叶形或矩形,所述矩形表现出宽度和高度,其中宽度可以显著大于高度,即宽度与高度之比为至少2,优选至少5,更优选至少10,最优选至少25,从而使得该实施方案中的单丝为带。复丝纱可以包括具有不同横截面形状的单个细长丝。优选地,复丝纱的单个细长丝具有圆形横截面形状。
包含在稀松布的纬纱中的复丝可为加捻的。复丝纱的加捻程度可在宽范围内变化。在一个实施方案中,复丝纱包括至少10个捻度每米长度,更优选至少30个捻度每米长度,以利于在稀松布的制造期间处理复丝纱,因为可能扰乱稀松布制造过程的单个细长丝伸出长丝束的风险降低。存在于复丝纱中的捻具有迫使单个细长丝的束具有用于复丝纱的大致圆形的总横截面的趋势。
然而,复丝纱可以包括减小的捻度,以使复丝纱在稀松布中呈现基本上平坦的取向。由于在复丝纱中仅存在有限数量的捻,单个细长丝具有更大的自由度,从而分布到彼此相邻布置的细长丝的单层中,或者分布到彼此相邻布置的细长丝的有限数量的层中,所述层布置在彼此的顶部上。复丝纱可以包括至多70个捻度每米长度,更优选最多50个捻度每米长度。
优选地,复丝纱包括至多70个捻度每米长度,更优选至多50个捻度每米长度,因为(太)高的加捻程度增加了加捻的复丝纱中的内应力,而不进一步改进稀松布制造期间的处理。
优选地,复丝纱的单跟细玻璃长丝具有在3μm至18μm范围内,更优选在4μm至13μm范围内,最优选在5μm至7μm范围内的直径。
稀松布可以包含粘结剂以改善稀松布的处理和/或改善稀松布的尺寸稳定性和加工性。优选地,粘结剂包括任何热塑性或热固性有机聚合物、共聚物或其任何混合物,例如聚乙烯醇PVA,丙烯酸酯,苯乙烯-丁二烯,乙烯,乙酸乙烯酯,苯乙烯-丙烯酸酯,聚丙烯酸乙烯酯或PVC增塑溶胶。
在本发明的范围内,应理解术语纤维是指短切纤维和长丝。短切纤维是具有特定的、在2至200mm范围内的相对短的长度的纤维。长丝是长度大于200mm,优选大于500mm,更优选大于1000mm的纤维。长丝甚至可以是实质上无端的,例如当经由连续挤出和通过喷丝头中的纺丝孔纺制长丝而形成时。
纤维的非织造层的纤维可以具有任何横截面形状,包括圆形,三叶形,多叶形或矩形,所述矩形表现出宽度和高度,其中宽度可以显著大于高度,即宽度与高度之比为至少2,优选至少5,更优选至少10,最优选至少25,从而使得该实施方案中的纤维为带。此外,所述纤维可以是单组分、双组分或甚至多组分纤维。
在一个实施方案中,纤维的非织造层中的纤维具有在1至25分特的范围内,优选在2至20分特的范围内,更优选在5至15分特的范围内,最优选在5至10分特的范围内的线密度,以向载体材料提供加工稳定性和质量规则性,同时保持足够的结构开放性,以使PVC增塑溶胶均匀渗透通过载体材料。单位分特将纤维的细度定义为以克计的它们的重量/10000米长度。
包含在载体材料中的纤维的非织造层可以是任何类型的非织造物,例如通过公知的方法制造的短切纤维非织造物,所述公知的方法例如梳理法,湿法成网法或气流成网法或其任意组合。纤维的非织造层还可以是由通过公知的纺粘法制备的长丝构成的非织造物,其中长丝从喷丝头挤出并随后作为长丝幅材放置在传送带上,随后结合所述幅材以形成纤维的非织造层,或者是通过两步法制备的长丝构成的非织造物,其中长丝被纺丝并缠绕在线轴上(优选以复丝纱的形式),随后是从线轴退绕纱线和/或复丝纱的步骤,任选地将复丝纱开松为基本上单个的长丝和/或长丝组,所述长丝组包括2至50根长丝,优选2至25根长丝,更优选2至10根长丝,以及将长丝和/或长丝组放置在移动传送带上作为长丝幅材,并结合所述幅材以形成纤维的非织造层。
优选地,纤维的非织造层中的纤维是长丝,以便为载体材料和/或衬垫的乙烯基地板覆盖物提供更高的拉伸强度和/或更高的撕裂强度。
一个或多个纤维的非织造层中的每一个由热塑性纤维构成各纤维的非织造层中的纤维总重量的至少50重量%,优选至少75重量%,更优选至少90重量%,甚至更优选至少95重量%,最优选100重量%,因为增加纤维的非织造层中的热塑性纤维的量增大拉伸强度,增大抗撕裂性和/或增大载体材料和(衬垫的)乙烯基地板覆盖物的柔性。
在一个实施方案中,每个纤维的非织造层由占纤维的非织造层中的纤维总重量的100重量%的热塑性纤维构成。
构成纤维的非织造层中的热塑性纤维的热塑性聚合物可为能够耐受在衬垫的乙烯基地板覆盖物制造过程中遇到的温度的任何类型的热塑性聚合物。纤维的非织造层中的热塑性纤维可优选包括聚酯,例如聚对苯二甲酸乙二醇酯(PET)(基于DMT或PTA),聚对苯二甲酸丁二醇酯(PBT),聚对苯二甲酸三亚甲基酯(PTT),聚萘二甲酸乙二醇酯(PEN)和/或聚乳酸(PLA),聚酰胺例如聚酰胺-6(PA6),聚酰胺-6,6(PA6,6)和/或聚酰胺-6,10(PA6,10),聚苯硫醚(PPS)聚乙烯酰亚胺(PEI)和/或聚甲醛(POM)和/或其任意共聚物或任意共混物。
热塑性纤维可包含以纤维总重量计至多25重量%的添加剂,例如纺丝助剂,填料,阻燃材料,UV抑制剂,结晶阻滞剂/促进剂,增塑剂,热稳定剂,抗微生物添加剂,着色剂(例如炭黑),或其任何组合。
尽管载体材料的一个或多个纤维的非织造层可以包含少量的玻璃纤维,但载体材料的每个纤维的非织造层由热塑性纤维构成各个纤维的非织造层总重量的至少50重量%,以与基于玻璃非织造物的载体材料相比(已知其具有很小的柔性和低撕裂强度),为衬垫的乙烯基地板覆盖物提供改进的抗撕裂性和柔性。术语“少量”应理解为意指小于每个纤维的非织造层总重量的50重量%,优选小于25重量%,更优选小于10重量%,甚至更优选小于5重量%。
因此,载体材料明确地不包括由50重量%或更多的玻璃纤维构成的纤维的非织造层。
纤维的非织造层中的玻璃纤维可以包括任何类型的玻璃(如E,C,S,R或AR(耐碱性))。特别地,AR-或E-玻璃由于其机械强度而是优选的。
在一个实施方案中,纤维的非织造层可以由纤维素纤维构成纤维的非织造层中的纤维总重量的至少50重量%,优选至少75重量%,更优选至少90重量%,甚至优选至少95重量%。
在一个实施方案中,纤维的非织造层由占纤维的非织造层中的纤维总重量的100重量%的纤维素纤维构成。
包含在载体材料中的一个或多个纤维的非织造层的总重量可以在10g/m2至250g/m2的范围内,优选在25g/m2至150g/m2的范围内,更优选在50g/m2至120g/m2的范围内,最优选在60g/m2至100g/m2的范围内,以为PVC增塑溶胶透过浸渍层而保持载体材料的结构足够开放,以提供浸渍层对载体材料的足够的机械粘附。纤维的非织造层的较低总重量导致浸渍层中PVC增塑溶胶的较少消耗。
在一个实施方案中,在每个纤维的非织造层中的热塑性纤维各自地优选由长丝构成,可以由单一类型的单组分纤维构成,其通过任何合适的结合技术结合,例如通过在两个压延机辊之间压延纤维幅材,通过机械针刺,通过水刺法,通过超声粘结或通过其任何组合。
在另一个实施方案中,(优选由长丝构成的)在纤维的非织造层中的热塑性纤维,可以包含至少两种不同类型的单组分纤维,每种类型的单组分纤维由不同化学构造的聚合物构成和/或具有不同的熔点。纤维的非织造层可以包括两种,三种或更多种不同类型的单组分纤维。优选地,纤维的非织造层由两种不同类型的单组分纤维组成。优选两种不同聚合物的熔点相差至少10℃。更优选地,熔点相差至少50℃。这种非织造层可以通过使纤维幅材经受具有较低熔点的聚合物的熔点范围内的温度而热结合。
聚合物的熔点通过差示扫描量热法测定,通过以10℃/分钟的速率将聚合物从0℃加热至聚合物完全熔化的温度(例如,至300℃的温度)。聚合物的熔融温度由吸热熔融峰的最大值处的温度定义。
在另一个实施方案中,在纤维的非织造层中的热塑性纤维优选由长丝组成,可以包含双组分纤维。双组分纤维是由具有不同化学构造和/或具有不同熔点的两种聚合物组成的纤维。纤维的非织造层可以包括两种,三种或更多种不同类型的双组分纤维。优选地,纤维的非织造层由一种类型的双组分纤维或两种不同类型的双组分纤维组成。在三种熟知类型的双组分纤维之间存在基本区别:并列型,芯鞘型和海岛型双组分纤维。在一个优选的实施方案中,包含在双组分纤维中的两种聚合物的熔点相差至少10℃。更优选地,熔点相差至少50℃。当由并列型和/或芯鞘型双组分纤维组成时,包含双组分纤维的这种非织造层可以通过使纤维幅材经受显示出较低熔点的聚合物的熔点范围内的温度而热结合。在优选的实施方案中,非织造载体主要由芯鞘型双组分纤维,优选长丝制成。主要理解为是指,包含在纤维的非织造层中的纤维的至少50%,优选至少75%,更优选至少90%,甚至更优选至少95%,最优选100%是芯鞘型双组分纤维。
优选地,芯/鞘双组分纤维中的芯/鞘比在95/5体积%和5/95体积%之间,更优选在90/10体积%和10/90体积%之间,最优选在75/25体积%和25/75体积%之间。
包含在第一(“一个”)纤维的非织造层中的热塑性纤维可以不同于包含在至少一个其它(“更多”)纤维的非织造层中的热塑性纤维,以优化在载体材料中的每个纤维的非织造层的性能,例如在施加多层浸渍基质的情况下对基质的最佳粘附。
优选地,包含在第一纤维的非织造层中的热塑性纤维与包含在载体材料中的每一个其它纤维的非织造层中的热塑性纤维相同,以简化载体材料的制造。
在优选的实施方案中,芯/鞘双组分纤维的鞘主要由聚酰胺,优选聚酰胺-6(PA6)组成,并且芯主要由聚酯,优选聚对苯二甲酸乙二醇酯(PET)组成。
不受理论的束缚,据信,由于纤维的非织造层在横向上的收缩和/或紧缩,在浸渍层中的PVC增塑溶胶胶凝期间现有技术的稀松布的纬纱的屈曲导致胶凝的浸渍层的不平表面,特别是当纬纱的屈曲在形成载体材料的表面的平面之外发生时,如在图1中示意性描绘的。稀松布包括在纵向上延伸的经纱(2)和在横向上延伸的纬纱(1)。纬纱(1)在PVC增塑溶胶的浸渍层的胶凝过程中屈曲。浸渍层由于纬纱(1)的屈曲而具有不规则的上表面(3)和不规则的下表面(4)。由于胶凝的浸渍层的不平坦的上表面(3),局部变化的量(即层厚度(D1,D2)不同)的包含发泡剂的PVC增塑溶胶将作为涂布在胶凝的浸渍层的不规则表面(3)上的发泡层施用。在涂布之后和在发泡层中的PVC增塑溶胶胶凝之后,涂层仍然可以具有平滑、平坦的上表面(5)。可以在涂布的发泡层的表面(5)上施加期望的油墨图案和耐磨层(6)。然而,局部变化的量(D1,D2)的包含发泡剂的PVC增塑溶胶将在发泡层固化(发泡)之后在最终衬垫的乙烯基地板覆盖物的表面(8)中诱发表面不规则。与在施加较小量(D2)的包含发泡剂的PVC增塑溶胶的位置处相比,在施加较大量(D1)的包含发泡剂的PVC增塑溶胶的位置处,在发泡层发泡之后,衬垫的乙烯基地板覆盖物的最终厚度将更高,导致最终衬垫的乙烯基地板覆盖物的表面(8)中的表面不规则。
此外,据信在纤维的非织造层横向上收缩或紧缩时由稀松布的纬纱(1)的屈曲引起的胶凝的浸渍层的不平坦表面(3,4)使得在胶凝的发泡层(5)上局部施加所需的油墨图案复杂化。虽然涂层和随后的发泡层的胶凝可能形成用于油墨的均匀表面(5),但是将难以确保在印刷单元和胶凝的发泡层的表面(5)之间、在待印刷的表面上施加均匀的压力,特别是当实际压力由与不规则胶凝的浸渍层的相对表面(4)直接接触的支撑辊提供的支撑决定时。最后,将可发泡的PVC增塑溶胶的背衬层(7)涂布在不规则的胶凝的浸渍层的相对表面(4)上。由于胶凝的浸渍层的不平坦的下表面(4),局部变化量(即层厚度不同)的包含发泡剂的PVC增塑溶胶将也作为涂布在胶凝的浸渍层的不规则表面(4)上的背衬层施用。由于背衬层可以经受压花步骤,并且当安装在地板上时,衬垫的乙烯基地板覆盖物的背面是不可见的,所以这种影响可能不太重要。
虽然预期与具有较高线密度的纱线相比,具有较低线密度的纱线刚性较低,并且因此预期其对压缩应力较不耐受并因此更易于屈曲,但令人惊讶地发现,包括包含具有28特克斯或更小的线密度的纬纱的稀松布的载体材料实际上防止或至少显著减少了在衬垫的乙烯基地板覆盖物中的印刷错误和/或表面不规则的形成。
载体材料可以有利地用于屋顶,地板或地毯复合产品,特别是用于(衬垫)乙烯基地板覆盖物中。
实施例
实施例1
基于包括纤维的非织造层和稀松布的载体制造衬垫的乙烯基地板覆盖物。载体材料由嵌在两个纤维的非织造层之间的稀松布组成。两个纤维的非织造层通过空气粘结穿过稀松布中的开口彼此热结合,从而通过彼此结合的两个纤维的非织造层的纤维的包封,将稀松布的经纱和纬纱一体化至载体材料中。
两个纤维的非织造层由具有7分特的线密度的芯-鞘双组分长丝组成,长丝的芯由聚对苯二甲酸乙二醇酯构成,并且鞘由聚酰胺-6构成,二者的比例为74/26体积%/体积%,两个纤维的非织造层的总重量为100g/m2。稀松布由在纵向上延伸的每厘米宽度1.3根玻璃纱和在横向上延伸的每厘米0.8根玻璃纱构成。在纵向上延伸的玻璃纱和在横向上延伸的玻璃纱都具有11特克斯的线密度。
衬垫的乙烯基材料没有表现出在纵向上延伸的褶皱,并且没有观察到在衬垫的乙烯基材料中的印刷错误。
比较例
基于包括纤维的非织造层和稀松布的载体材料制造六种衬垫的乙烯基地板覆盖物。在每个比较例中的载体材料由嵌在两个纤维的非织造层之间的稀松布组成。两个纤维的非织造层通过空气粘结穿过稀松布中的开口彼此热结合,从而通过彼此结合的两个纤维的非织造层的纤维的包封,将稀松布的经纱和纬纱一体化至载体材料中。
两个纤维的非织造层由具有7分特的线密度或10分特的线密度的芯-鞘双组分长丝组成,长丝的芯由聚对苯二甲酸乙二醇酯构成,并且鞘由聚酰胺-6构成,二者的比例为74/26体积%/体积%,两个纤维的非织造层的总重量为75g/m2。稀松布由在纵向上延伸的每厘米宽度1.3根玻璃纱和在横向上延伸的每厘米0.8根玻璃纱构成,或由在纵向上延伸的每厘米宽度0.65根玻璃纱和在横向上延伸的每厘米0.8根玻璃纱构成,或由在纵向上延伸的每厘米宽度0.65根玻璃纱和在横向上延伸的每厘米0.4根玻璃纱构成。在所有三种稀松布中,在纵向上延伸的玻璃纱和在横向上延伸的玻璃纱都具有34特克斯的线密度。
尽管所有六种类型的衬垫的乙烯基材料都没有表现出在纵向上延伸的褶皱,但是在沿横向延伸的玻璃纱所位于的那些位置附近观察到印刷错误。
Claims (13)
1.一种用于制造复合产品的载体材料,所述复合产品包含所述载体材料和浸渍的基质,所述载体材料包含一个或多个纤维的非织造层以及稀松布,其中每个纤维的非织造层由热塑性纤维构成各纤维的非织造层中的纤维总重量的至少50重量%,所述稀松布包含玻璃纤维或高模量聚酯纤维的纬纱,玻璃纬纱具有28特克斯或更小,优选20特克斯或更小,更优选15特克斯或更小的线密度,高模量聚酯纬纱具有50特克斯或更小,优选40特克斯或更小,更优选30特克斯或更小的线密度。
2.根据权利要求1所述的载体材料,其中稀松布包含玻璃纤维或高模量聚酯纤维的经纱,所述经纱具有100特克斯或更小,优选50特克斯或更小,更优选28特克斯或更小,甚至更优选20特克斯或更小,最优选15特克斯或更小的线密度。
3.根据前述权利要求中任一项所述的载体材料,其中稀松布包含纬纱和/或经纱,所述纬纱和/或经纱具有至少25GPa的模量。
4.根据前述权利要求中任一项所述的载体材料,其中稀松布的纬纱为复丝玻璃纱,并且其中复丝玻璃纱的单根玻璃长丝具有在3μm至18μm范围内的直径。
5.根据前述权利要求中任一项所述的载体材料,其中稀松布的纬纱和/或经纱由E-玻璃或AR-玻璃制成。
6.根据前述权利要求中任一项所述的载体材料,其中稀松布包含粘结剂,所述粘结剂包含任意热塑性或热固性有机聚合物、共聚物或其任意混合物,特别是聚乙烯醇PVA,丙烯酸酯,苯乙烯-丁二烯,乙烯,乙酸乙烯酯,苯乙烯-丙烯酸酯,聚丙烯酸乙烯酯或PVC增塑溶胶。
7.根据前述权利要求中任一项所述的载体材料,其中至少一个,优选每个纤维的非织造层由热塑性纤维构成各纤维的非织造层中的纤维总重量的至少75重量%,优选至少90重量%,更优选至少95重量%。
8.根据前述权利要求中任一项所述的载体材料,其中纤维的非织造层包含单组分纤维,优选至少两种不同类型的单组分纤维,或包含双组分纤维。
9.根据权利要求7至8中任一项所述的载体材料,其中该一个或多个纤维的非织造层是热结合的。
10.根据前述权利要求中任一项所述的载体材料,其中该一个或多个纤维的非织造层和稀松布彼此连接以形成一体化的载体。
11.根据前述权利要求中任一项所述的载体材料,其中稀松布嵌入在两个纤维的非织造层之间。
12.一种复合产品,其包含根据权利要求1至11中任一项所述的载体材料和浸渍的基质。
13.根据权利要求12所述的复合产品,其中所述复合产品为乙烯基地板覆盖物。
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PCT/EP2015/059167 WO2015165886A1 (en) | 2014-04-29 | 2015-04-28 | Carrier material for vinyl floor covering |
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JP6785754B2 (ja) | 2020-11-18 |
RU2670860C9 (ru) | 2018-11-30 |
KR102398706B1 (ko) | 2022-05-17 |
RU2016145409A3 (zh) | 2018-08-28 |
WO2015165886A1 (en) | 2015-11-05 |
TW201544666A (zh) | 2015-12-01 |
CN106660303B (zh) | 2019-01-29 |
KR20170018820A (ko) | 2017-02-20 |
RU2016145409A (ru) | 2018-05-30 |
EP3137294B1 (en) | 2018-04-11 |
EP3137294A1 (en) | 2017-03-08 |
US11623425B2 (en) | 2023-04-11 |
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CA2947224C (en) | 2021-05-18 |
US20170043551A1 (en) | 2017-02-16 |
CA2947224A1 (en) | 2015-11-05 |
TWI663311B (zh) | 2019-06-21 |
RU2670860C2 (ru) | 2018-10-25 |
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