CN1671550B - 含有低延伸率织物的可呼吸材料及其制造方法 - Google Patents

含有低延伸率织物的可呼吸材料及其制造方法 Download PDF

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CN1671550B
CN1671550B CN038178982A CN03817898A CN1671550B CN 1671550 B CN1671550 B CN 1671550B CN 038178982 A CN038178982 A CN 038178982A CN 03817898 A CN03817898 A CN 03817898A CN 1671550 B CN1671550 B CN 1671550B
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low elongation
layer
breathable material
coating
tissue layer
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CN1671550A (zh
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G·K·琼斯
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Clopay Plastic Products Co Inc
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Clopay Plastic Products Co Inc
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Nonwoven Fabrics (AREA)
  • Finishing Walls (AREA)

Abstract

包括低延伸率织物层和位于其上的微孔涂层的可呼吸材料。微孔涂层中含有结晶聚合物组合物和填料。该材料适用于包括房屋包裹和其他建筑应用的各种领域中。制造可呼吸材料的方法是：用含有结晶聚合物组合物和填料的混合物对低延伸率织物层进行挤压涂布，在低延伸率织物层上形成涂层，并增量拉伸经过涂布的非织造层，形成微孔涂层。

Description

含有低延伸率织物的可呼吸材料及其制造方法
发明领域
本发明涉及含有低延伸率织物的可呼吸材料，适合于作为房屋包裹材料等建筑材料，还涉及这种可呼吸材料的制造方法。
发明背景
房屋包裹材料通常被贴附或固定在建筑物墙壁框架或覆盖物的外表面上，特别是用于寒冷气候中。房屋包裹材料必须能渗透水蒸气，使水蒸气从固定薄膜的墙壁中逸出，从而防止水对墙壁造成破坏和/或生长霉菌或类似物。另一方面，房屋包裹材料应该具有足够强的防止空气和液体渗透的能力，从而使墙壁与风，雨或其他降水作用隔离。而且，房屋包裹材料应该具有足够的拉伸性能和物理性能，例如断裂强度，延伸率，撕裂强度，收缩率和抗刺强度，从而防止在安装时受到损坏并有助于提高耐用性。
为了提供适用于建筑和类似耐用领域的具有足够强度和韧性的房屋包裹材料和其他可呼吸材料，通常要求使用坚固和/或强韧的非织造和/或织造材料。通常，这些非织造和织造材料具有较低的延伸能力，例如小于约30％的延伸率，这限制了形成复合材料可以使用的技术。
Sheth的美国专利4929303公开了包括可呼吸薄膜和非织造织物的可呼吸复合房屋包裹材料，可呼吸薄膜是由线性低密度聚乙烯形成的，非织造织物是由交向层压纤维形成的。形成可呼吸薄膜的方法是：将前体薄膜浇铸挤压在压辊上，拉伸前体薄膜使其具有渗透性，加热非织造织物，并将加热的织物按压在薄膜上，使织物和可呼吸薄膜粘合。从这些连续加工步骤中可知，所公开房屋包裹材料的制造方法是繁琐和昂贵的。
因此，需要提出改进的可呼吸材料，包括那些可能使用较强或较韧非织造层的材料，以及制造这种材料的方法。
发明概述
因此，本发明的一个目的是提供克服了现有技术各种缺点的新颖可呼吸材料，特别适合于要求高强度的应用中，例如建筑应用。另一个目的是提供制造这种可呼吸材料的新颖方法。
本发明能达到这些和其他目的。在一个实施例中，本发明涉及可呼吸材料。可呼吸材料中包括低延伸率织物层和位于其上的微孔涂层。微孔涂层中含有结晶聚合物组合物和填料。
在另一个实施例中，本发明涉及可呼吸房屋包裹材料。可呼吸房屋包裹材料包括低延伸率聚烯烃非织造层和位于其上的微孔涂层，微孔涂层中含有高密度聚乙烯和填料。
在另一个实施例中，本发明涉及制造可呼吸材料的方法。该方法包括：用含有结晶聚合物组合物和填料的混合物挤压涂布低延伸率织物层，在低延伸率织物层上形成涂层，增量拉伸经过涂布的层，形成微孔涂层。
本发明可呼吸材料的优点是表现出理想的强度，可呼吸性和液体渗透性，能采用本发明的方法简单地制造。通过以下具体说明，本发明可呼吸材料，房屋包裹材料及其制造方法的这些和其他目的及优点是更显而易见的。
具体说明
本发明涉及用于各种领域的可呼吸材料。在一个实施例中，可呼吸材料适合于作为建筑材料，包括但并不限于房屋包裹材料，防水板，屋面衬垫材料，例如用于木瓦，瓷砖或类似物下方，作为沥青油纸替代品，和/或用于其他建筑应用中。但是，本领域技术人员从以上说明中可知，可呼吸材料的其他特定应用和用途也在本发明的范围内。
本发明的可呼吸材料中包括低延伸率织物层和位于其上的微孔涂层。在本发明范围中，术语“低延伸率”通常是指材料的延伸率小于约30％，例如按照ASTM D5034进行测量。低延伸率层应当具有能防止涂层的微孔发生明显堵塞的结构。在一个实施例中，低延伸率层通常具有类似筛网或纱网的开孔结构。通常还要求形成低延伸率层的材料是比较坚硬和强韧的。例如，在优选实施例中，按照ASTM D-882测量时，低延伸率层可以具有至少约20磅/英寸的拉伸强度。
低延伸率层可以是织造或非织造织物，如需要或者是织造织物和非织造织物的组合。另外，可以用其他任何合乎需要的材料形成低延伸率织物层。在一个实施例中，低延伸率层是一种或多种聚烯烃形成的非织造或织造织物，例如聚乙烯，聚丙烯或其混合。在特定实施例中，低延伸率层是包括聚烯烃交向层压(cross-laminated)开孔网的非织造层。在更具体的实施例中，低延伸率层是包括聚乙烯交向层压开孔网的非织造层。这些材料可以从Atlanta Nisseki CLAF，Inc.以商品名CLAF
Figure S03817898219950411D000031
购得。CLAF
Figure S03817898219950411D000032
材料分成适用于本发明的具有不同物理性质组合的系列等级。在一个实施例中，低延伸率层是包括聚乙烯交向层压开孔网的非织造层，其基重大于约0.7盎司/平方码。
在另一个实施例中，低延伸率织物层是含有纺粘材料的非织造层，例如纺粘聚烯烃，例如聚乙烯，聚丙烯或其组合。适用纺粘非织造织物具有大于约0.7盎司/平方码的基重。在更具体的实施例中，低延伸率层是含有纺粘聚丙烯的非织造层，具有等于或大于约1盎司/平方码的基重，更优选是基重大于约1.5盎司/平方码的纺粘聚丙烯。适用于可呼吸材料的纺粘非织造材料可以具有大约2到15旦尼尔的细度，更优选是大约10到12旦尼尔，具有该范围较大值细度的纺粘材料优选用于房屋包裹材料应用中。这种纺粘非织造织物是本领域中已知的，可以从Reemay，Inc.以商品名TYPAR购得。
在另一个实施例中，低延伸率层是含有快纺无纺材料，例如从DuPont以商品名TYVEK购得的快纺高密度聚乙烯非织造材料的非织造层。快纺无纺材料具有各种基重，适合于作为本发明的可呼吸材料。在某些实施例中，快纺无纺材料的基重在大约0.7到4盎司/平方码范围内。
还可以使用本领域已知的其他织造和/或非织造材料作为本发明可呼吸材料的低延伸率织物层。
位于本发明可呼吸材料中低延伸率织物上的微孔涂层中含有结晶聚合物组合物和填料。在本发明的范围中，术语“结晶聚合物组合物”是指超过50％的聚合组分以晶状形式存在的聚合组合物。本发明的发明人认识到，结晶聚合物组合物与填料能在低延伸率织物层所能承受的较小拉伸率情况下产生微孔。涂层中可以单独或组合使用各种晶状聚合物。在特定实施例中，晶状聚合物包括高密度聚乙烯(HDPE)，这是本领域中已知的，是指测得晶体含量和密度至少是约0.94克/立方厘米的聚乙烯。在进一步的实施例中，结晶聚合物组合物的密度大于约0.945克/立方厘米。
适用于个别薄膜层的填料包括但并不限于各种有机和/或无机材料。在特定实施例中，填料可以包括一种或多种无机材料，例如金属氧化物，金属氢氧化物，金属碳酸盐和类似物。优选填料包括但并不限于碳酸钙，硅藻土，二氧化钛及其混合。选择合适的填料粒径，影响涂层中的微孔大小，从而影响材料产物的可呼吸性。通常，合适填料的平均粒径是大约0.5到5微米，不过还可以使用具有更小或更大粒径的填料。可选填料具有帮助其分散在结晶聚合物组合物中的表面涂层，从而提高填料的防水能力，和/或增加填料与结晶聚合物组合物的不相容性，并在填料附近形成微孔。
微孔涂层中填料的含量适合于提供是需要的可呼吸性。通常，填料含量占微孔涂层重量的大约25到75％。
涂层可以是形成于织物层上的单个层或多个层。在一个实施例中，涂层包括单层薄膜，以下进一步具体说明，可以通过挤压涂布方法形成织物层。在进一步的实施例中，涂层包括多层(两层或更多层)薄膜，可以通过两层或多层薄膜的挤出层压方法形成。在这个实施例中，至少一个薄膜层中含有结晶聚合物组合物和填料，但并不一定要求所有薄膜层中都含有结晶聚合物组合物和填料，不过这种情况是允许的。在特定实施例中，涂层中包括三个层压薄膜，是通过在两个外层之间挤出层压一个核心层而形成的，核心层中含有结晶聚合物组合物和填料，两个外层是由含有50％或更小重量比的结晶聚合物组合物，例如中密度聚乙烯，低密度聚乙烯，线性低密度聚乙烯，聚丙烯或类似物和填料形成的。
可选本发明的可呼吸材料中进一步含有第二织造或非织造织物层，其中的微孔涂层位于低延伸率织物层和第二织物层之间。最好第二非织造层与低延伸率织物层具有相似的形态和组成，或者第二织物层具有不同的形态和/或组成。在一个实施例中，第二织物层包括纺粘非织造层，例如纺粘聚丙烯。
可以根据材料的预期应用控制本发明材料的可呼吸性。作为房屋包裹材料时，按照ASTM E-96E测量，优选具有大于约150克/平方米×24小时的水蒸气透过率，较优选大于约300克/平方米×24小时，更优选大于约500克/平方米×24小时。通常，不要求这种材料具有高水蒸气透过率，其水蒸气透过率小于约2000克/平方米×24小时。能够理解具有更高水蒸气透过率的材料也同样在本发明的范围中。
在本发明的一个实施例中，可呼吸材料的制造方法是：用含有结晶聚合物组合物和填料的混合物挤压涂布低延伸率织物层，在低延伸率层上形成涂层，增量拉伸经过涂布的低延伸率层，形成微孔涂层。如上所述，结晶聚合物组合物和填料能在低延伸率非织造层能够承受的较小拉伸率情况下形成微孔涂层。在一个实施例中，经过涂布的低延伸率层被增量拉伸至永久延伸率小于约5％。在另一个实施例中，经过涂布的低延伸率层被增量拉伸至永久延伸率小于约2％，更优选小于约1％。在进一步的实施例中，经过涂布的低延伸率层被增量拉伸，而不使材料发生永久延伸。
例如，使用本领域中众所周知的技术，能从挤压机的压模中挤出，并通过气刀或其他冷却设备进入压辊之间的辊隙，形成薄膜涂层。挤压是在等于或高于涂布材料结晶聚合物组合物熔点的温度下进行的，通常是大约400-500°F。通常，辊隙是在金属辊和橡胶辊之间形成的。可以从供料辊输送低延伸率织物层，使涂层薄膜和低延伸率织物料片通过压辊之间的辊隙，使涂层与低延伸率织物表面粘合。然后增量拉伸所形成经过涂布的低延伸率织物。
更具体地说，可以在横向进行增量拉伸，称之为CD啮合拉伸，也可以在纵向进行，称之为MD啮合拉伸，或者同时在横向和纵向进行。
CD啮合拉伸机中通常具有一对位于平行机轴上的类似齿轮单元。机轴位于两个机器侧板之间，下机轴位于固定轴承上，上机轴位于垂直滑动单元轴承上。通过用调节螺丝操纵的楔形单元，能够在垂直方向上调节滑动单元。调节螺丝使楔形单元向外或向内运动，能够使垂直滑动单元上下滑动，使上啮合辊与下啮合辊的齿进一步咬合或者脱离。操纵安装在侧板上的千分尺，能够指示啮合辊齿的咬合深度。通常使用汽缸将滑动单元固定在其较低咬合位置上，紧靠着调节楔形单元，从而对抗在拉伸材料所产生的向上的力。还可以缩回这些汽缸，使上下啮合辊彼此脱离，从而使材料穿过啮合设备或者与安全回路一起发挥作用，安全回路在被激活时能打开所有机械捏合点。CD啮合拉伸机的传动装置必须能在除了以较高摩擦系数啮合拉伸材料之外，操纵上下啮合辊。
CD啮合单元通常是由固态材料机械加工而成的，最好将其描述为两个不同直径圆盘的交错层叠。在一个实施例中，啮合盘大约是6英寸直径，大约0.031英寸厚度，在其边缘上具有完全半径。分隔啮合盘的间隔盘大约是5.5英寸直径，大约0.069英寸厚度。这种结构的两个压辊能啮合至0.231英寸，为每个侧面的材料留出0.019英寸间隙。CD啮合单元结构具有0.100英寸间距。
MD啮合拉伸装置通常与CD啮合拉伸装置相同，区别在于啮合辊的设计。MD啮合辊与细距正齿轮非常相似。在一个实施例中，辊直径是5.933英寸，0.100英寸间距，30径节，14又1/2°压力角，基本上是长齿顶截头齿轮。第二遍操作可以在齿轮滚刀补偿为0.010英寸的压辊上进行，提供更窄的齿和更大的间隙。咬合深度大约为0.090英寸时，该结构在侧面为材料厚度留出大约0.010英寸的间隙。
可以调节啮合辊的咬合深度，从而在涂层中形成微孔。在一个实施例中，啮合辊的咬合深度至少是约0.012英寸，更优选是大约0.012英寸到0.020英寸，0.030英寸或更深。因为啮合单元通常能产生较大的咬合深度，所以很重要的一点是，设备中结合能使两个啮合辊的机轴在抬升或降低上机轴时保持平行的装置。必须保证一个啮合辊的齿总是位于另一个啮合辊的齿之间，从而防止啮合齿之间发生破坏性的物理接触。这种平行关系能通过齿条和齿轮的排列实现，其中，固定齿条以垂直于滑动单元的方式被固定在每个侧板上。机轴横穿侧板，并在每个垂直滑动单元的轴承上工作。齿轮位于机轴的每个末端上，并与齿条咬合，产生要求的平行运动。
在一个实施例中，仅在纵向上增量拉伸可呼吸材料。结果是，能很简单地使用带褶皱压辊将可呼吸材料制成房屋包裹材料，这些褶皱是通过在垂直位置取向上以纵向进行啮合而形成的。
通常，本发明的可呼吸材料能在低延伸率条件下具有可呼吸性，能采用比传统可呼吸材料更低的延伸率技术制造。在较低延伸率加工方法中，可以在拉伸过程中使用较小的啮合辊咬合深度。在低延伸率水平情况下获得理想水平的微孔性，能以比传统可呼吸材料更小的程度拉伸材料，从而降低和/或基本消除随着更精确拉伸操作可能发生的材料损坏现象，更精确的拉伸操作是获得含有低密度聚合组合物挤压涂层的可呼吸材料所要求的。
因此，在一个实施例中，使经过涂布的低延伸率织物传送通过可选预加热辊，至增量拉伸部分，使经过涂布的低延伸率织物通过纵向(MD)增量拉伸辊，形成可呼吸的，被增量拉伸的材料。可选使材料通过附加拉伸部分，接受进一步拉伸。例如，使材料传送通过可选预加热辊，并通过横向(CD)增量拉伸辊。
实施例1
在该实施例中，制备了本发明的可呼吸材料。具体而言，将含有密度大于约0.945克/立方厘米的高密度聚乙烯的涂层挤出层压在含有聚乙烯交向层压开孔网的非织造层表面上。非织造层以商品名CLAF
Figure S03817898219950411D000071
获得，基重大约是0.91盎司/平方码。CLAF非织造织物在纵向和横向具有大约20％的延伸率。涂层另一个表面上挤出层压有基重约为1盎司/平方码，细度约为2旦尼尔的纺粘聚丙烯非织造织物。涂层基重为30克/平方米。用大约15密尔的咬合深度对制得材料进行CD啮合拉伸，用大约30密尔的咬合深度进行MD啮合拉伸，在高密度聚乙烯挤出涂层中形成微孔，提供可呼吸材料。可呼吸材料不能渗透液体，具有大于约150克/平方米×24小时的潮湿蒸汽透过率。测量材料透气率的方法是：在测试样品一侧引入90磅/平方英寸的空气，测量通过样品的空气体积流速。测得的透气率是83毫升/分/平方厘米。
为了进行对比，用相似基重的线性低密度聚乙烯挤压涂层代替含高密度聚乙烯的挤压涂层，制备类似材料。以20密尔的咬合深度进行CD啮合拉伸，以30密尔的咬合深度进行MD啮合拉伸。对比材料不能渗透液体，是可呼吸性的，按照上述透气率测试产生约78毫升/分/平方厘米的气流。
因此，从加工本发明可呼吸材料方法中所用小于对比材料的CD咬合深度可知，本发明可呼吸材料在低延伸率情况下具有相当或更好的可呼吸性。令人吃惊和没有预料到的是，本发明的可呼吸材料在低延伸率情况下具有很好的微孔性。而且，本发明可呼吸材料的优点是，在低延伸率情况下具有很好的可呼吸性，因此能够减少和/或基本消除在精确拉伸操作时发生织物损坏的情况。
实施例2
本实施例证明了包括多层涂层的本发明可呼吸材料。36克/平方厘米的三层“ABA”涂层被挤出层压在2.3盎司/平方码，低延伸率纺粘聚丙烯(SBPP)非织造织物层上。每个“A”层中含有9克/平方米的组合物层，其中包括45％聚丙烯，50％碳酸钙和5％低密度聚乙烯(LDPE)。核心“B”层是18克/平方米的含有53％碳酸钙，41％高密度聚乙烯，4％二氧化钛，1％CaO母粒和1％加工助剂的层。在层压体以200英尺/分的速度通过未经加热金属辊之后立刻进行啮合。MD啮合的咬合深度是40密尔。不对样品进行CD啮合。按照实施例1中所述测量透气率为41立方厘米/分/平方厘米。
为了进行对比，制造包括多层微孔涂层的对比可呼吸材料，方法是：将36克/平方米的三层“ABA”涂层挤出层压在2.3盎司/平方码的SBPP非织造织物层上。每个“A”层都含有9克/平方米的组合物层，组合物中含有45％聚丙烯，50％碳酸钙和5％LDPE。核心“B”层是含有53％碳酸钙，41％中密度聚乙烯，4％二氧化钛，1％CaO母粒和1％加工助剂的18克/平方米的层。在层压体以200英尺/分的速度通过未经加热的金属辊之后对其进行啮合。MD啮合的咬合深度是40密尔。不对样品进行CD啮合。测得透气率是21立方厘米/分/平方厘米。
这里所作的具体说明和实施例仅是对性质的例证，而不是对本发明由权利要求所限定范围的限制。进一步的实施例和样品对阅读了本说明书的本领域技术人员是显而易见的，并且在权利要求的范围内。

Claims (27)

1.一种可呼吸材料，包括低延伸率织物层和位于其上的微孔涂层，所述低延伸率织物层按照ASTM D5034测量的延伸率小于约30％，所述微孔涂层中含有结晶聚合物组合物和填料，所述结晶聚合物组合物有至少50重量％以晶状形式存在。
2.如权利要求1所述的可呼吸材料，其特征在于，所述低延伸率织物层包括低延伸率非织造层。
3.如权利要求2所述的可呼吸材料，其特征在于，所述低延伸率非织造层包括聚烯烃交向层压开孔网。
4.如权利要求3所述的可呼吸材料，其特征在于，所述低延伸率非织造层包括基重大于约24克/平方米的聚乙烯交向层压开孔网。
5.如权利要求2所述的可呼吸材料，其特征在于，所述低延伸率非织造层包括纺粘聚丙烯。
6.如权利要求5所述的可呼吸材料，其特征在于，所述纺粘聚丙烯具有大于约24克/平方米的基重。
7.如权利要求5所述的可呼吸材料，其特征在于，所述纺粘聚丙烯具有等于或大于约34克/平方米的基重。
8.如权利要求1所述的可呼吸材料，其特征在于，所述结晶聚合物组合物包括高密度聚乙烯。
9.如权利要求1所述的可呼吸材料，其特征在于，所述填料包括碳酸钙。
10.如权利要求1所述的可呼吸材料，其特征在于，所述微孔涂层包括单个层。
11.如权利要求1所述的可呼吸材料，其特征在于，所述微孔涂层包括两个或更多个层。
12.如权利要求1所述的可呼吸材料，其特征在于，所述材料进一步包括第二织物层，涂层位于低延伸率织物层和第二织物层之间。
13.一种可呼吸房屋包裹材料，包括如权利要求1所述的可呼吸材料，其中所述结晶聚合物组合物包含高密度聚乙烯。
14.如权利要求13所述的可呼吸房屋包裹材料，其特征在于，所述低延伸率织物层包括聚烯烃非织造层。
15.如权利要求14所述的可呼吸房屋包裹材料，其特征在于，所述低延伸率聚烯烃非织造层包括基重大于约24克/平方米的聚乙烯交向层压开孔网。
16.如权利要求14所述的可呼吸房屋包裹材料，其特征在于，所述低延伸率聚烯烃非织造层包括基重大于约24克/平方米的纺粘聚丙烯。
17.一种制造如权利要求1所述可呼吸材料的方法，包括用含有结晶聚合物组合物和填料的组合物挤压涂布低延伸率织物层，所述低延伸率织物层按照ASTM D5034测量的延伸率小于约30％，从而在低延伸率织物层上形成涂层，增量拉伸经过涂布的低延伸率织物层，形成微孔涂层。
18.如权利要求17所述的方法，其特征在于，所述低延伸率织物层包括低延伸率非织造层，涂层形成于非织造层上。
19.如权利要求18所述的方法，其特征在于，以纵向增量拉伸所述经过涂布的非织造层。
20.如权利要求18所述的方法，其特征在于，增量拉伸所述经过涂布的非织造层至延伸率小于约2％。
21.如权利要求18所述的方法，其特征在于，所述低延伸率非织造层包括基重大于约24克/平方米的聚乙烯交向层压开孔网。
22.如权利要求18所述的方法，其特征在于，所述低延伸率非织造层包括基重大于约24克/平方米的纺粘聚丙烯。
23.如权利要求17所述的方法，其特征在于，所述结晶聚合物组合物包括高密度聚乙烯。
24.如权利要求1所述的可呼吸材料，其特征在于，所述低延伸率织物层包括低延伸率织造层。
25.如权利要求24所述的可呼吸材料，其特征在于，所述低延伸率织造层由聚乙烯，聚丙烯或其混合物形成。
26.如权利要求17所述的方法，其特征在于，所述低延伸率织物层包括低延伸率织造层。
27.如权利要求26所述的方法，其特征在于，所述低延伸率织造层由聚乙烯，聚丙烯或其混合物形成。
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