TW201733804A - 輕薄高強度複合基材及其製造方法 - Google Patents
輕薄高強度複合基材及其製造方法 Download PDFInfo
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Abstract
本發明係關於一種輕薄高強度複合基材及其製造方法。該輕薄高強度複合基材包括一織物、一彈性層及一水性聚氨酯面層。該織物係由高強力纖維或高強力單絲織造而成,該高強力纖維或該高強力單絲之材質係為聚對苯二甲酸乙二酯(PET),該織物具有一第一表面及一第二表面,該第二表面相對於該第一表面。該彈性層貼合於該織物之該第一表面。該水性聚氨酯面層貼合於該織物之該第二表面。藉此,可製得輕量薄型化、抗污、耐摩擦及高物性強度之複合基材。
Description
本發明係關於一種基材及其製造方法,特別係關於一種輕薄高強度複合基材及其製造方法。
習知常見之鞋用基材,主要區分為一般人工皮革及編織網布。
一般人工皮革不論是乾式製程或是溼式製程,其厚度均在0.8至1.3mm之間,會使用這些厚度區間,主要是為了保有人工皮革的手感。當厚度低於0.8mm時,皮革會呈現塑膠紙感;當厚度大於1.3mm時,則皮革太硬挺。雖然,透過控制厚度,可以調整及改變人工皮革的手感,但作為鞋用基材,厚度及重量仍無法有效的減輕及變薄。
除了人工皮革之外,近年,也常見使用編織的網布,來做為鞋面基材,而編織網布主要使用長纖維,並藉由織造技術編織出不同花色或不同組織的網布,進而使用於鞋用基材。然而,編織網布雖具輕量化效果,但網布的物性不佳,特別是耐摩擦更差,因為長纖維紗線容易受到摩擦而形成毛絲現象,而且網布也無法像人工皮革具有多樣的顏色及表面紋路變化。此外,紗線的抗汙效果也不佳,不容易清潔,若使用於運動鞋材,易造成破損與髒污。
習知鞋用基材如下列先前技術專利文獻分析:
1. TW M456105
作法:使用編織鞋面。
缺點:色水限制不易變化,且耐磨耗性不佳。
2. TW M451012
作法:使用編織鞋面。
缺點:色水限制不易變化,且耐磨耗性不佳。
3. TW 201410170
作法:使用複合纖維。
缺點:色水限制不易變化,且手感偏硬。
4. TW I470126
作法:使用低強度、低模數之複合纖維。
缺點:只適合應用於需容易撕裂的標籤布或做為容易撕裂布料之基材,物性強度不佳。
5. TW I465341
作法:使用複合織布。
缺點:容易被織物限制其表面變化,且抗汙效果不佳。
基於上述分析,有必要提供一創新且具進步性之輕薄高強度複合基材及其製造方法,以解決上述習知缺失。
本發明提供一種輕薄高強度複合基材,包括一織物、一彈性層及一水性聚氨酯面層。該織物係由高強力纖維或高強力單絲織造而成,該高強力纖維或該高強力單絲之材質係為聚對苯二甲酸乙二酯(PET),該織物具有一第一表面及一第二表面,該第二表面相對於該第一表面。該彈性層貼合於該織物之該第一表面。該水性聚氨酯面層貼合於該織物之該第二表面。
本發明另提供一種輕薄高強度複合基材之製造方法,包括以下步驟:提供一纖維原料,該纖維原料係為聚對苯二甲酸乙二酯
(PET);利用一長纖維紡絲機或單絲紡絲機將該纖維原料熔融進行紡絲,並以多段羅拉延伸機進行牽伸,以製得高強力纖維或高強力單絲;將高強力纖維或高強力單絲織造成一織物,該織物具有一第一表面及一第二表面,該第二表面相對於該第一表面;貼合一彈性層於該織物之該第一表面;及貼合一水性聚氨酯面層於該織物之該第二表面,以製得輕薄高強度複合基材。
本發明以聚對苯二甲酸乙二酯(PET)所製得之高強力纖維或高強力單絲可織造成織物,而利用該織物與彈性層及水性聚氨酯面層分別貼合,可製得輕量薄型化、抗污、耐摩擦及高物性強度之複合基材。
為了能夠更清楚瞭解本發明的技術手段,而可依照說明書的內容予以實施,並且為了讓本發明所述目的、特徵和優點能夠更明顯易懂,以下特舉較佳實施例,並配合附圖,詳細說明如下。
10‧‧‧輕薄高強度複合基材
12‧‧‧織物
12A‧‧‧第一表面
12B‧‧‧第二表面
12F‧‧‧高強力纖維,高強力單絲
14‧‧‧彈性層
16‧‧‧水性聚氨酯面層
16W‧‧‧紋路結構
18‧‧‧黏著層
20‧‧‧乾式貼合機
S31~S35‧‧‧步驟
圖1顯示本發明輕薄高強度複合基材之結構示意圖;圖2顯示本發明輕薄高強度複合基材之另一結構示意圖;圖3顯示本發明輕薄高強度複合基材之製造方法流程圖;圖3A顯示本發明輕薄高強度複合基材之製造方法中之一高強力纖維或高強力單絲之製程示意圖;圖3B顯示依據本發明輕薄高強度複合基材之製造方法將高強力纖維織造成一織物之示意圖;圖3C顯示依據本發明輕薄高強度複合基材之製造方法貼合一彈性層於織物之示意圖;圖3D顯示依據本發明輕薄高強度複合基材之製造方法貼合一水性聚氨酯面層於織物之示意圖;圖3E顯示依據本發明輕薄高強度複合基材之製造方法設置一黏著層於織物與水性聚氨酯面層之間之示意圖;及
圖4顯示本發明用以貼合水性聚氨酯面層於織物之乾式貼合機的示意圖。
參閱圖1,其係顯示本發明輕薄高強度複合基材之結構示意圖。本發明之輕薄高強度複合基材10包括一織物12、一彈性層14及一水性聚氨酯面層16。
該織物12係由高強力纖維或高強力單絲12F織造而成,該高強力纖維或該高強力單絲12F之材質係為聚對苯二甲酸乙二酯(PET)。且較佳地,該高強力纖維或該高強力單絲12F之纖維強度為7至14g/den。此外,該織物12具有一第一表面12A及一第二表面12B,該第二表面12B相對於該第一表面12A。
該彈性層14係貼合於該織物12之該第一表面12A。在本實施例中,該彈性層14之材質係為熱塑性聚氨酯彈性體、熱塑性聚醯胺彈性體或熱塑性聚酯彈性體。
該水性聚氨酯面層16係貼合於該織物12之該第二表面12B。在本實施例中,該水性聚氨酯面層16之黏度為2000至4600cps,且其固型份為33至45%。此外,該水性聚氨酯面層16可具有紋路結構16W。
參閱圖2,其係顯示本發明輕薄高強度複合基材之另一結構示意圖。如圖2所示,在另一實施例中,該輕薄高強度複合基材10可包括一黏著層18,該黏著層18設置於該織物12與該水性聚氨酯面層16之間,以提高該織物12與該水性聚氨酯面層16之接合強度。較佳地,該黏著層18係為水性糊劑或高固形份糊劑,且該水性糊劑之黏度為7000~16000cps,該高固形份糊劑之固形份為70%~90%。
圖3顯示本發明輕薄高強度複合基材之製造方法流程圖。圖3A顯示本發明輕薄高強度複合基材之製造方法中之一高強力纖維或高強力單絲之製程示意圖。圖3B顯示依據本發明輕薄高強度複合基材之製
造方法將高強力纖維織造成一織物之示意圖。圖3C顯示依據本發明輕薄高強度複合基材之製造方法貼合一彈性層於織物之示意圖。圖3D顯示依據本發明輕薄高強度複合基材之製造方法貼合一水性聚氨酯面層於織物之示意圖。
參閱圖3之步驟S31,提供一纖維原料,該纖維原料係為聚對苯二甲酸乙二酯(PET)。較佳地,該纖維原料的特性黏度(IV)為0.9至1.1。
配合參閱圖3之步驟S32及圖3A,利用一長纖維紡絲機或單絲紡絲機將該纖維原料熔融進行紡絲,並以多段羅拉延伸機進行牽伸,以製得高強力纖維或高強力單絲12F。在此步驟中,該長纖維紡絲機或該單絲紡絲機之紡絲箱溫度為295至315℃,而捲取速度為2200至3500m/min。此外,所製得之高強力纖維或高強力單絲12F之纖維強度為7至14g/den,而纖維規格為150den/48f或0.12mm線徑。
配合參閱圖3之步驟S33及圖3B,將高強力纖維或高強力單絲12F織造成一織物12,該織物12具有一第一表面12A及一第二表面12B,該第二表面12B相對於該第一表面12A。在此步驟中,係可以圓編機、經編機、梭織機或非梭織機(例如噴水式織機,噴氣式織機)將高強力纖維或高強力單絲12F織造成該織物12。
配合參閱圖3之步驟S34及圖3C,貼合一彈性層14於該織物12之該第一表面12A。在此步驟中,係以一貼合機(圖未繪出)貼合該彈性層14於該織物12之該第一表面12A,該貼合機可以是履帶式貼合機、羅拉式貼合機或平板熱壓式貼合機。此外,該彈性層14之材質係可為熱塑性聚氨酯彈性體、熱塑性聚醯胺彈性體或熱塑性聚酯彈性體。
圖4顯示本發明用以貼合水性聚氨酯面層於織物之乾式貼合機的示意圖。配合參閱圖3之步驟S35、圖3D及圖4,貼合一水性聚氨酯面
層16於該織物12之該第二表面12B,以製得輕薄高強度複合基材10。在此步驟中,係以一乾式貼合機20貼合該水性聚氨酯面層16於該織物12之該第二表面12B。較佳地,該水性聚氨酯面層16之黏度為2000至4600cps,而其固型份為33至45%。此外,該水性聚氨酯面層16係可以離型紙形成紋路結構16W。
參閱圖3E,其係顯示依據本發明輕薄高強度複合基材之製造方法設置一黏著層於織物與水性聚氨酯面層之間之示意圖。為提高該織物12與該水性聚氨酯面層16之接合強度,在此步驟中,可另設置一黏著層18於該織物12與該水性聚氨酯面層16之間。較佳地,該黏著層18係為水性糊劑或高固形份糊劑,且該水性糊劑之黏度為7000~16000cps,該高固形份糊劑之固形份為70%~90%。
本發明所製得之輕薄高強度複合基材10之拉伸強度可達20至50kg/2.54cm(ASTM D1682),而其撕裂強度可達4至16kg(ASTM D2261)。
本發明以聚對苯二甲酸乙二酯(PET)所製得之高強力纖維或高強力單絲可織造成織物,而利用該織物與彈性層及水性聚氨酯面層分別貼合,可製得輕量薄型化、抗污、耐摩擦及高物性強度之複合基材,該複合基材可應用於鞋材加工。
茲以下列實例予以詳細說明本發明,唯並不意謂本發明僅侷限於此等實例所揭示之內容。
發明例1之纖維原料為高黏度聚對苯二甲酸乙二酯(PET),其特性黏度(IV)為0.95。酯粒先輸送到乾燥桶內進行乾燥,乾燥溫度設定為170℃,經7小時乾燥後,控制酯粒含水率小於30ppm,之後再輸送到長纖維紡絲機之設備進行紡絲,其中,紡絲箱溫度設定為300℃,冷
卻風溫為14℃,冷卻風相對濕度為50%,紡絲的過程中,會經過多段延伸羅拉,利用多段延伸羅拉,將長纖維進行4.09倍的牽伸(drawing),提高纖維的強度,同時降低纖維的伸長率,再經卷繞機(winder),以2500m/min的捲繞速度,捲取成絲餅狀(bobbin),製得高強力纖維,完成的長纖維規格為150den/48f,纖維物性為強度7.5g/den、伸長率15%。
將上述製得之高強力纖維,以梭織機進行織造,其中經密為95根/inch,緯密為75根/inch,製得一厚度為0.25mm,基重118g/m2的基布。準備熱塑性聚氨酯薄膜,熔點118℃,厚度0.2mm,蕭式硬度為80 shore A,使用羅拉貼合機,其中羅拉溫度設定為120℃,羅拉的操作壓力,設定為20kg/cm2,將熱塑性聚氨酯彈性體薄膜與基布進行貼合,製得半成品,再準備水性聚氨酯溶液,黏度為3100cps,在乾式塗布機的第一道塗布台,調整塗布間隙為0.1mm進行水性PU的塗布,使PU塗布在離型紙上,再一起進入第一道烘箱,烘箱長度為12m,共分六區加熱區,依序設定為80℃、90℃、110℃、120℃、120℃、130℃,當水性PU離開第一道烘箱後,再經第二道塗布台,塗布間隙一樣為0.1mm,進行第二道水性PU的塗布,塗布完後,進入第二道烘箱,此時烘箱長度為8m,共分四區加熱,依序設定為100℃、110℃、120℃、120℃,當烘乾完畢後,上面有已乾燥PU膜的離型紙離開烘箱時,會經過一加熱羅拉,羅拉溫度設定為120℃,將前述半成品,其中沒有貼合熱塑性聚氨酯薄膜之表面與水性PU經過加熱羅拉,進行熱壓貼合,即得到輕量薄型化、抗污、耐摩擦及高物性之複合基材。該複合基材的物性如下:拉伸強度可達32.9kg/2.54cm,而撕裂強度可達9.2kg。
發明例2之纖維原料為高黏度聚對苯二甲酸乙二酯(PET),其特性黏度(IV)為1.05。酯粒先輸送到乾燥桶內進行乾燥,乾燥溫度設定為170℃,經7小時乾燥後,控制酯粒含水率小於30ppm,之後再輸送到長纖維紡絲機之設備進行紡絲,其中,紡絲箱溫度設定為305℃,冷卻風溫為12℃,冷卻風相對濕度為60%,紡絲的過程中,會經過多段延伸羅拉,利用多段延伸羅拉,將長纖維進行4.21倍的牽伸(drawing),提高纖維的強度,同時降低纖維的伸長率,再經卷繞機(winder),以2600m/min的捲繞速度,捲取成絲餅狀(bobbin),製得高強力纖維,完成的長纖維規格為300den/96f,纖維物性為強度12.2g/den、伸長率13%。
將上述製得之高強力纖維,以經編機進行織造,其中經密為140根/inch,可製得一厚度為0.35mm,基重155g/m2的基布。準備熱塑性聚氨酯薄膜,熔點108℃,厚度0.15mm,蕭式硬度為70 shore A,使用羅拉貼合機,其中羅拉溫度設定為115℃,羅拉的操作壓力,設定為30kg/cm2,將熱塑性聚氨酯薄膜與基布進行貼合,製得半成品,再準備水性聚氨酯溶液,黏度為2750cps,在乾式塗布機的第一道塗布台,調整塗布間隙為0.1mm進行水性PU的塗布,使PU塗布在離型紙上,再一起進入第一道烘箱,烘箱長度為12m,共分六區加熱區,依序設定為90℃、100℃、115℃、120℃、120℃、125℃,當水性PU離開第一道烘箱後,再經第二道塗布台,塗布間隙一樣為0.1mm,準備水性聚氨酯糊劑,黏度為9500cps,進行第二道水性糊劑的塗布,塗布完後,進入第二道烘箱,此時烘箱長度為8m,共分四區加熱,依序設定為110℃、115℃、115℃、120℃,當烘乾完畢後,上面有已
乾燥PU膜的離型紙離開烘箱時,會經過一加熱羅拉,羅拉溫度設定為115℃,將前述的半成品,其中沒有貼合熱塑性聚氨酯薄膜之表面與水性PU糊劑經過加熱羅拉,進行熱壓貼合,即得到輕量薄型化、抗污、耐摩擦及高物性之複合基材。該複合基材的物性如下:拉伸強度可達45.6kg/2.54cm,而撕裂強度可達12.3kg。
發明例3之纖維原料為高黏度聚對苯二甲酸乙二酯(PET),其特性黏度(IV)為1.1。酯粒先輸送到乾燥桶內進行乾燥,乾燥溫度設定為170℃,經7小時乾燥後,控制酯粒含水率小於30ppm,之後再輸送到長纖維紡絲機之設備進行紡絲,其中,紡絲箱溫度設定為310℃,冷卻風溫為10℃,冷卻風相對濕度為55%,紡絲的過程中,會經過多段延伸羅拉,利用多段延伸羅拉,將長纖維進行4.23倍的牽伸(drawing),提高纖維的強度,同時降低纖維的伸長率,再經卷繞機(winder),以2750m/min的捲繞速度,捲取成絲餅狀(bobbin),製得高強力纖維,完成的長纖維規格為100den/36f,纖維物性為強度9.1g/den、伸長率9%。
將上述製得之高強力纖維,以噴水式織機進行織造,其中經密為120根/inch,緯密為90根/inch,可製得一厚度為0.3mm,基重130g/m2的基布。準備熱塑性聚醯胺彈性體薄膜,熔點158℃,厚度0.15mm,蕭式硬度為90 shore A,使用羅拉貼合機,其中羅拉溫度設定為165℃,羅拉的操作壓力,設定為35kg/cm2,將熱塑性聚醯胺彈性體薄膜與基布進行貼合,製得半成品,再準備水性聚氨酯溶液,黏度為2350cps,在乾式塗布機的第一道塗布台,調整塗布間隙為0.1mm進行水性PU的塗布,使PU塗布在離型紙上,再一起進入第一道烘
箱,烘箱長度為12m,共分六區加熱區,依序設定為90℃、100℃、115℃、120℃、120℃、125℃,當水性PU離開第一道烘箱後,再經第二道塗布台,塗布間隙為0.07mm,準備水性聚氨酯糊劑,黏度為12000cps,進行第二道水性糊劑的塗布,塗布完後,進入第二道烘箱此時烘箱長度為8m,共分四區加熱,依序設定為110℃、115℃、115℃、120℃進行乾燥,當烘乾完畢後,上面有已乾燥PU膜的離型紙離開烘箱時,會經過一加熱羅拉,羅拉溫度設定為165℃,將前述的半成品,其中沒有貼合熱塑性聚醯胺彈性體薄膜之表面與水性PU糊劑經過加熱羅拉,進行熱壓貼合,即得到輕量薄型化、抗污、耐摩擦及高物性之複合基材。該複合基材的物性如下:拉伸強度可達42.6kg/2.54cm,而撕裂強度可達15.9kg。
發明例4之纖維原料為高黏度聚對苯二甲酸乙二酯(PET),其特性黏度(IV)為1.1。酯粒先輸送到乾燥桶內進行乾燥,乾燥溫度設定為170℃,經7小時乾燥後,控制酯粒含水率小於30ppm,之後再輸送到長纖維紡絲機之設備進行紡絲,其中,紡絲箱溫度設定為305℃,冷卻風溫為8℃,冷卻風相對濕度為65%,紡絲的過程中,會經過多段延伸羅拉,利用多段延伸羅拉,將長纖維進行5.4倍的牽伸(drawing),提高纖維的強度,同時降低纖維的伸長率,再經卷繞機(winder),以850m/min的捲繞速度,捲取成絲餅狀(bobbin),製得高強力單絲纖維,完成的單絲長纖維規格為0.12mm線徑,纖維物性為強度8.6g/den、伸長率30%。
將上述製得之高強力單絲纖維,以經編式織機進行織造,其中經密為50根/inch,緯密為50根/inch,可製得一厚度為0.12mm,基重
65g/m2的基布。準備熱塑性聚酯彈性體薄膜,熔點122℃,厚度0.15mm,蕭式硬度為75 shore A,使用羅拉貼合機,其中羅拉溫度設定為125℃,羅拉的操作壓力,設定為20kg/cm2,將熱塑性聚酯彈性體薄膜與基布進行貼合,製得半成品,再準備水性聚氨酯溶液,黏度為1850cps,在乾式塗布機的第一道塗布台,調整塗布間隙為0.1mm進行水性PU的塗布,使PU塗布在離型紙上,再一起進入第一道烘箱,烘箱長度為12m,共分六區加熱區,依序設定為80℃、90℃、110℃、120℃、120℃、130℃,當水性PU離開第一道烘箱後,再經第二道塗布台,塗布間隙一樣為0.1mm,進行第二道水性PU的塗布,塗布完後,進入第二道烘箱,此時烘箱長度為8m,共分四區加熱,依序設定為100℃、110℃、120℃、120℃進行乾燥,當烘乾完畢後,上面有已乾燥PU膜的離型紙離開烘箱時,會經過一加熱羅拉,羅拉溫度設定為135℃,將前述的半成品,其中沒有貼合熱塑性聚酯彈性體薄膜之表面與水性PU經過加熱羅拉,進行熱壓貼合,即得到輕量薄型化、抗污、耐摩擦及高物性之複合基材。該複合基材的物性如下:拉伸強度可達39.3kg/2.54cm,而撕裂強度可達18.8kg。
上述實施例僅為說明本發明之原理及其功效,並非限制本發明,因此習於此技術之人士對上述實施例進行修改及變化仍不脫本發明之精神。本發明之權利範圍應如後述之申請專利範圍所列。
10‧‧‧輕薄高強度複合基材
12‧‧‧織物
12A‧‧‧第一表面
12B‧‧‧第二表面
12F‧‧‧高強力纖維,高強力單絲
14‧‧‧彈性層
16‧‧‧水性聚氨酯面層
16W‧‧‧紋路結構
Claims (18)
- 一種輕薄高強度複合基材,包括:一織物,係由高強力纖維或高強力單絲織造而成,該高強力纖維或該高強力單絲之材質係為聚對苯二甲酸乙二酯(PET),該織物具有一第一表面及一第二表面,該第二表面相對於該第一表面;一彈性層,貼合於該織物之該第一表面;及一水性聚氨酯面層,貼合於該織物之該第二表面。
- 如請求項1之輕薄高強度複合基材,其中該高強力纖維或該高強力單絲之纖維強度為7至14g/den。
- 如請求項1之輕薄高強度複合基材,其中該水性聚氨酯面層之黏度為2000至4600cps。
- 如請求項1之輕薄高強度複合基材,其中該水性聚氨酯面層之固型份為33至45%。
- 如請求項1之輕薄高強度複合基材,其中該彈性層之材質係為熱塑性聚氨酯彈性體、熱塑性聚醯胺彈性體或熱塑性聚酯彈性體。
- 如請求項1之輕薄高強度複合基材,另包括一黏著層,該黏著層設置於該織物與該水性聚氨酯面層之間。
- 如請求項6之輕薄高強度複合基材,其中該黏著層係為水性糊劑或高固形份糊劑。
- 如請求項7之輕薄高強度複合基材,其中該水性糊劑之黏度為7000~16000cps。
- 如請求項7之輕薄高強度複合基材,其中該高固形份糊劑之固形份為70%~90%。
- 一種輕薄高強度複合基材之製造方法,包括以下步驟:(a)提供一纖維原料,該纖維原料係為聚對苯二甲酸乙二酯(PET);(b)利用一長纖維紡絲機或單絲紡絲機將該纖維原料熔融進行紡絲,並以多段羅拉延伸機進行牽伸,以製得高強力纖維或高強力單絲;(c)將高強力纖維或高強力單絲織造成一織物,該織物具有一第一表面及一第二表面,該第二表面相對於該第一表面;(d)貼合一彈性層於該織物之該第一表面;及(e)貼合一水性聚氨酯面層於該織物之該第二表面,以製得輕薄高強度複合基材。
- 如請求項10之輕薄高強度複合基材之製造方法,其中步驟(a)之纖維原料的特性黏度(IV)為0.9至1.1。
- 如請求項10之輕薄高強度複合基材之製造方法,其中步驟(b)製得之高強力纖維或高強力單絲之纖維強度為7至14g/den。
- 如請求項10之輕薄高強度複合基材之製造方法,其中步驟(d)係以一貼合機貼合該彈性層於該織物之該第一表面。
- 如請求項10之輕薄高強度複合基材之製造方法,其中步驟(e)係以一乾式貼合機貼合該水性聚氨酯面層於該織物之該第二表面。
- 如請求項10之輕薄高強度複合基材之製造方法,其中步驟(d)之該水性聚氨酯面層之黏度為2000至4600cps。
- 如請求項10之輕薄高強度複合基材之製造方法,其中步驟(e)之該水性聚氨酯面層之固型份為33至45%。
- 如請求項10之輕薄高強度複合基材之製造方法,其中步驟(e)另包括設置一黏著層於該織物與該水性聚氨酯面層之間。
- 如請求項17之輕薄高強度複合基材之製造方法,其中該黏著層係為水性糊劑或高固型份糊劑。
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CN108340632A (zh) * | 2017-01-25 | 2018-07-31 | 清远广硕技研服务有限公司 | 织物结构、加厚织物结构以及织物结构制造方法 |
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US20100092726A1 (en) | 2006-12-22 | 2010-04-15 | Basf Se | Composite material, particularly synthetic leather |
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