TWI648160B - 立體織物複合材料的製造方法、塗佈機以及使用該方法得到之複合材料 - Google Patents
立體織物複合材料的製造方法、塗佈機以及使用該方法得到之複合材料 Download PDFInfo
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- TWI648160B TWI648160B TW107108993A TW107108993A TWI648160B TW I648160 B TWI648160 B TW I648160B TW 107108993 A TW107108993 A TW 107108993A TW 107108993 A TW107108993 A TW 107108993A TW I648160 B TWI648160 B TW I648160B
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Abstract
本發明提供一種立體織物複合材料的製造方法,其係具有網孔的立體織物作為基材,製造該基材表面具有塗層的立體織物複合材料的方法,包括以下步驟:提供一樹脂組成物;塗佈步驟;以及開孔步驟。
Description
本發明係關於一種立體織物複合材料的製造方法,特別是關於一種立體織物複合材料的製造方法、塗佈機以及使用該方法得到之複合材料。
立體織物或網布(3-D fabric或spacer fabric),具有結構強韌富彈性且因多孔而質輕的特點,在各個層面的應用,正持續被開發中,例如服飾、鞋材、交通運輸、建築、農用及醫療等創新應用。於本說明書,所謂立體織物複合材料,係指立體織物的全部表面或一部分表面,具有塗層的複合材料。上述塗層可由各種無機或有機化合物、聚合物、共聚物、樹脂等所構成,只要是可賦予立體織物不同於周圍無塗層的區域不同的指定的物理及/或化學特性。在立體織物表面附加塗層,可賦予立體織物特殊的功能,藉由只在立體織物的特定區域賦予塗層,可在特定區域具有與周圍無塗層的區域不同的物理及/或化學特性,例如國際公開專利WO2006/079602記載的結合熱塑性材料與立體織物作為骨折固定裝置、美國專利第6482167號記載的骨科鑄造技術等,因為立體織物具有透氣性佳及質輕的特性,再加上熱塑性材料的機械強度及可塑性,非常適合取代傳統石膏作為骨折的固定夾板或支持板。
然而,在製作立體織物複合材料時,一般使用塗佈或含浸法,然而使用含浸法製作立體織物複合材料時,通常是使用構成塗層的材料溶解於溶劑的溶液,將立體織物浸漬於該溶液中,再移除溶劑,而得到立體織物複合材料。如此的製造方法,需要使用溶劑,且除去溶劑時需耗費大量能源,除製造的安全性不佳外,製造成本高且對環境不友善。另一
方面,使用塗佈法製作立體織物複合材料時,通常的塗佈法所使用的塗料為了促進浸潤於立體織物中,也有包含溶劑的情況,而且因通常的塗佈法所製作的塗膜,皆為完整塗膜,因為立體織物所具有的網孔填滿塗料,導致立體織物失去透氣性。然而,立體織物複合材料具有透氣的性質,在許多應用上是必要的特徵,所以如何製造立體織物複合材料,使立體織物複合材料具有透氣性,成為產業亟需的技術。
鑒於上述之發明背景,為了符合產業上之要求,本發明之目的之一在於提供一種立體織物複合材料的製造方法,藉由連續塗膜於立體織物表面後實施開孔步驟,除可製造具有透氣性的立體織物複合材料外,降低生產成本,提高生產效率。
再者,本發明之目的之一在於提供一種塗佈機,藉由使用滾輪對滾輪的塗佈方式,收捲時使用滾輪時可連續地製造膜狀的立體織物複合材料,直接裁切切時可連續地製造板狀的立體織物複合材料。
為了達到上述目的,根據本發明一實施態樣,提供一種立體織物複合材料的製造方法,其係具有網孔的立體織物作為基材,製造該基材表面具有塗層的立體織物複合材料的方法,包括以下步驟:提供一樹脂組成物;將該樹脂組成物,藉由一塗佈機構,形成塗膜於該基材的一側或兩側的表面,得到一表面具有塗膜的基材的塗佈步驟;以及將該表面具有塗膜的基材,藉由一開孔機構,破壞塗膜在網孔間的彎液面(meniscus),得到表面開孔的立體織物複合材料的開孔步驟。
再者,根據本發明另一實施態樣,提供一種塗佈機,其係用於在具有網孔的基材上形成有孔塗膜的塗佈裝置,包括:將構成塗膜的材料成為流體的塗佈裝置,用以在基材表面形成塗膜;複數傳動滾輪,連續傳遞長條狀的基材;開孔裝置,使通過該開孔裝置的基材形成連通基材的兩表面之貫穿孔,使該基材具有透氣性。
再者,根據本發明另一實施態樣,提供一種立體織物複合材料,其係藉由使用上述本發明的立體織物複合材料的製造方法或上述本發明的塗佈機製造而得。
根據本發明的立體織物複合材料的製造方法及/或塗佈機,可連續地製造具有透氣性的立體織物複合材料外,降低生產成本,提高生產效率。根據本發明的立體織物複合材料的製造方法及/或塗佈機所製造的立體織物複合材料,可具有質輕、透氣性佳、追隨性佳、操作性佳等的優點,依據複合材料的特性,可應用於例如服飾、鞋材、交通運輸、建築、農用及醫療等的各種領域。
1‧‧‧立體織物複合材料
10a,10b‧‧‧外部層
20‧‧‧中間層
30‧‧‧立體織物
40‧‧‧塗層
100‧‧‧塗佈機
110‧‧‧前處理裝置
105a,105b,105c‧‧‧傳送滾輪
120a,120b‧‧‧模頭
125a,125b‧‧‧塗佈滾輪
140a,140b‧‧‧壓入滾輪
130‧‧‧熱滾輪
150‧‧‧開孔裝置
160‧‧‧冷卻裝置
170‧‧‧切割機
180a,180b‧‧‧壓入及塗佈滾輪
圖1係表示根據本發明的立體織物複合材料的製造方法之流程圖。
圖2係表示關於本發明的立體織物複合材料的剖面圖。
圖3係表示圖2所示的關於本發明的立體織物複合材料的上視圖。
圖4係表示根據本發明的塗佈機之一例的示意圖。
圖5係表示根據本發明的塗佈機構或塗佈裝置之一例的示意圖。
圖6係表示根據本發明的塗佈機構或塗佈裝置之一例的示意圖。
圖7係表示根據本發明的塗佈機構或塗佈裝置之一例的示意圖。
圖8係表示根據本發明的開孔機構或開孔裝置之一例的示意圖。
有關本發明之前述及其他技術內容、特點與功效,在以下配合參考圖式之一較佳實施例的詳細說明中,將可清楚的呈現。以下實施例中所提到的方向用語,例如:上、下、左、右、前或後等,僅是參考附加圖式的方向。因此,使用的方向用語是用來說明並非用來限制本發明。此外,「A層(或元件)設置於B層(或元件)上」之用語,並不限定為A層直接貼覆接觸B層表面的態樣,例如A層與B層中間尚間隔其他積層亦為該用語所涵蓋範圍。圖式中,相同的元件係以相同的符號表示。圖式中的各構成元件的比例,僅供清楚說明,實際大小並未依照圖式中的比例繪製。
以下,藉由較佳實施態樣,具體地說明本發明,但本發明不限於該等實施態樣,在不脫離本發明的要旨之範圍內,可進行各種變形或變更。
圖1係表示根據本發明的立體織物複合材料的製造方法之流程圖。本發明的立體織物複合材料的製造方法,其係具有網孔的立體織物作為基材,製造該基材表面具有塗層的立體織物複合材料的方法,包括以下步驟:提供一樹脂組成物;將該樹脂組成物,藉由一塗佈機構,形成塗膜於該基材的一側或兩側的表面,得到一表面具有塗膜的基材的塗佈步驟(S1);以及將該表面具有塗膜的基材,藉由一開孔機構,破壞塗膜在網孔間的彎液面(meniscus),得到表面開孔的立體織物複合材料的開孔步驟(S2)。本發明的立體織物複合材料的製造方法可更包含熟成步驟(S3),在經過該開孔步驟後,所得之立體織物複合材料放置於溫度設定為該樹脂組成物具有流動性的溫度的環境(例如玻璃轉化溫度Tg以上或熔點以上),進行一特定期間的熟成處理。再者,本發明的製造方法可更包含基材前處理步驟(SP)。如圖1所示,本發明的立體織物複合材料的製造方法的基材前處理步驟(SP)、塗佈步驟(S1)、開孔步驟(S2)及熟成步驟(S3),可具有各種組合,但不限於圖1所示的例,例如作為變形例,各步驟可進行1次或2次以上。具體地,例如可進行塗佈步驟2次,分別在基材表面形成塗膜。
圖2係表示關於本發明的立體織物複合材料的剖面圖,其中(a)表示2層外部層10a,10b及中間層20所構成的立體織物30,(b)表示塗層40覆蓋於外部層10a,10b及中間層20的表面上所構成的立體織物複合材料1。圖3(a)表示圖2(a)所示的立體織物30的上視圖及圖3(b)表示圖2(b)所示的立體織物複合材料1的上視圖。
立體織物30,係2層外部層10a,10b及中間層20所構成,2層外部層10a,10b具有例如菱形的網孔,中間層為單絲(mono yarn),結構像三明治般堆疊,也稱為三明治立體網布,主要是由高分子合成纖維組成,可由精密經編機機台編織而成,2層外部層10a,10b間有密網支撐,使得表面的網狀結構不會產生太大的變形,增強了布料的機械性質及色彩牢固度。立體網布能夠廣泛地應用於服飾、鞋材、床墊、帽材、透氣鞋墊、運動防護材、醫療複合材等。立體織物30,亦可由市售品取得。
塗層40,可藉由本發明的製造方法,形成於2層外部層10a,
10b及中間層20的表面。樹脂組成物可由選自聚酯、聚氨酯、聚醯胺、聚醇所成群的至少一種無規共聚物或嵌段共聚物所構成。需注意的是如圖3所示,塗層40形成於立體織物30的表面後,仍存在有網孔50,具有立體網孔結構。此外,網孔50的縮小率,亦即(塗層形成前的網孔50的平均直徑-形成後的網孔50的平均直徑)/形成前的網孔50的平均直徑之比值,較理想為80%以下,更理想為50%以下,更加理想為40%以下。具體地,本發明的立體織物複合材料,根據ASTM D737的透氣率為100cfm(ft3/min)以上,較理想為300cfm以上,更理想為500cfm以上。
再者,於一實施例,該無規共聚物或嵌段共聚物,可在該相變化溫度以下具有108Pa以上的楊氏模數。再者,根據ASTM D790的三點彎曲的抗彎折試驗,使用寬約14mm、厚度約7.5mm的測試片,測試速度3.2mm/min,支撐點及壓子半徑為9mm,支撐點距離為85mm,變形量5%內無斷裂點產生,所得的數值為抗彎折強度,本發明的立體織物複合材料的抗彎折強度可為50kgf/cm2以上。該無規共聚物或嵌段共聚物,較理想為聚酯共聚物。但本發明的立體織物複合材料的製造方法,不限於使用上述例示的樹脂組成物。
於熟成步驟,其溫度可設定為樹脂組成物具有流動性的溫度,例如該樹脂組成物的玻璃轉化溫度Tg或熔點Tm以上,例如(熔點+10℃)以上。熟成處理的時間,隨熟成溫度而異,例如5分鐘~24小時,考慮生產性,10分鐘~8小時較理想。
於基材前處理步驟,在塗佈步驟前,將基材通過一前處理機構,進行前處理,活化基材表面,提高基材與樹脂組成物的黏著性。前處理機構,具體地例如包括可實施選自電漿處理、電暈處理、紫外線照射、臭氧處理、錨定處理、膨潤處理及預熱處理所成群的至少1種或2種以上的組合之機構。較理想為預熱處理。
於一實施例,該塗佈機構包括淋膜裝置、熱壓裝置或熱滾輪裝置。
於一實施例,上述之方法中,該開孔機構包括選自接觸式開孔機構及非接觸式開孔機構所成群的至少1種或2種以上的組合。於一實
施例,上述之方法中,該接觸式開孔機構包括表面具有針狀結構的平板或滾輪。於一實施例,上述之方法中,該非接觸式開孔機構包括低週波震盪器、高週波震盪器或烤箱。
於一實施例,上述之方法中,塗佈步驟後,可更包括藉由至少一組壓入滾輪,使該構成塗膜的材料滲入基材中的步驟。
再者,根據本發明的另一實施態樣之塗佈機,其係用於在具有網孔的基材上形成有孔塗膜的塗佈裝置,包括:將構成塗膜的材料成為流體的塗佈裝置,用以在基材表面形成塗膜;複數傳動滾輪,連續傳遞長條狀的基材;開孔裝置,使通過該開孔裝置的基材形成連通基材的兩表面之貫穿孔,使該基材具有透氣性。此處,所謂貫穿孔,不限於垂直於基材兩表面的空孔,只要是連通基材的兩表面,氣體可流通的孔洞即可。
於一實施例,塗佈機中,該開孔裝置包括選自接觸式開孔裝置及非接觸式開孔裝置所成群的至少1種或2種以上的組合。於一實施例,塗佈機中,該接觸式開孔裝置包括表面具有針狀結構的平板或滾輪。於一實施例,塗佈機中,該非接觸式開孔裝置包括低週波震盪器、高週波震盪器或烤箱。
於一實施例,塗佈機可更包括至少一組壓入滾輪,位於該構成塗膜的材料藉由該塗佈裝置形成塗膜於基材後,藉由調整該組壓入滾輪間的距離或表面溫度,使該構成塗膜的材料滲入基材中。
於一實施例,塗佈機中,該塗佈裝置為一擠出機。
於一實施例,上述塗佈機,可更包括冷卻裝置及/或切割機。
再者,於傳送基材的路徑中,依需要,上述塗佈機可包括熱滾輪或加熱區域,亦可包括冷卻區域。
再者,構成塗佈機構或塗佈機的各構成零件,依需要,可進行離型處理,離型處理例如含氟塗膜表面處理或聚矽氧(silicone)表面處理等,但不限於上述例。例如上述具有針狀結構的平板或滾輪,進行離型處理較理想。再者,構成塗佈機構的各構成零件,依需要,可進行表面鏡面處理等。
上述製造步驟或使用塗佈機時,塗膜可形成於基材的一表面
或兩表面,塗膜形成於基材的兩表面時,可同時形成,亦可分別形成,塗膜的厚度會影響所得之立體複合材料的開孔率,依據所使用的立體織物的厚度、所期望的開孔率及複合材料所期望的硬度,可任意地調整。在通常的應用領域,塗膜的範圍例如為0.02mm~0.5mm的範圍,較理想為0.05mm~0.2mm的範圍,或者較理想為立體織物的厚度的50%以下,更理想為立體織物的厚度的20%以下,更加理想為立體織物的厚度的10%以下。
再者,根據本發明的另一實施態樣之立體織物複合材料,其係利用上述本發明的方法製造而得或使用上述本發明的塗佈機製造而得。
圖4係表示根據本發明的塗佈機之一例的示意圖,但是本發明的塗佈機不限於包括圖中的所有構成,可以依需要做任意的選擇及組合。例如,塗佈機可以不具備前處理裝置。塗佈機100包括前處理裝置110、傳送滾輪105a,105b,105c等、模頭120a,120b、塗佈滾輪125a,125b、壓入滾輪140a,140b、熱滾輪130(可用加熱環境取代或不使用)、開孔裝置150、冷卻裝置160及切割機170等。圖5~7係表示根據本發明的塗佈機構或塗佈裝置之其他變形例的示意圖,其中180a及180b表示壓入及塗佈滾輪。圖8係表示根據本發明的開孔機構或開孔裝置150之一例的示意圖。上述圖式僅用以具體說明本發明,但本發明的構成不限於上述圖式所示的例。
綜上所述,根據本發明的立體織物複合材料的製造方法及/或塗佈機,可連續地製造具有透氣性的立體織物複合材料外,降低生產成本,提高生產效率。根據本發明的立體織物複合材料的製造方法及/或塗佈機所製造的立體織物複合材料,可具有質輕、透氣性佳、追隨性佳、操作性佳等的優點,依據複合材料的特性,可應用於例如服飾、鞋材、交通運輸、建築、農用及醫療等的各種領域。
以上雖以特定實施例說明本發明,但並不因此限定本發明之範圍,只要不脫離本發明之要旨,熟悉本技藝者瞭解在不脫離本發明的意圖及範圍下可進行各種變形或變更。另外本發明的任一實施例或申請專利範圍不須達成本發明所揭露之全部目的或優點或特點。此外,摘要部分和標題僅是用來輔助專利文件搜尋之用,並非用來限制本發明之權利範圍。
Claims (16)
- 一種立體織物複合材料的製造方法,其係具有網孔的立體織物作為基材,製造該基材表面具有塗層的立體織物複合材料的方法,包括以下步驟:提供一樹脂組成物,該樹脂組成物為選自聚酯、聚氨酯、聚醯胺、聚醇所成群的至少一種無規共聚物或嵌段共聚物所構成;將該樹脂組成物,藉由一塗佈機構,形成塗膜於該基材的一側或兩側的表面,得到一表面具有塗膜的基材的塗佈步驟;以及將該表面具有塗膜的基材,藉由一開孔機構,破壞塗膜在網孔間的彎液面(meniscus),得到表面開孔的立體織物複合材料的開孔步驟;其中該表面開孔的立體織物複合材料所具有的網孔的縮小率為50%以下,且根據ASTM D737的透氣率為100cfm(ft3/min)以上,在相變化溫度以下具有108Pa以上的楊氏模數。
- 如申請專利範圍第1項所述之方法,更包括:一熟成步驟,在經過該開孔步驟後,所得之立體織物複合材料放置於溫度設定為該樹脂組成物具有流動性的溫度的環境,進行一特定期間的熟成處理。
- 如申請專利範圍第1或2項所述之方法,更包括:一基材前處理步驟,在塗佈步驟前,將基材通過一前處理機構,進行前處理,活化基材表面,提高基材與樹脂組成物的黏著性。
- 如申請專利範圍第1或2項所述之方法,其中該塗佈機構包括淋膜裝置、熱壓裝置或熱滾輪裝置。
- 如申請專利範圍第1或2項所述之方法,其中該開孔機構包括選自接觸式開孔機構及非接觸式開孔機構所成群的至少1種或2種以上的組合。
- 如申請專利範圍第5項所述之方法,其中該接觸式開孔機構包括表面具有針狀結構的平板或滾輪。
- 如申請專利範圍第5項所述之方法,其中該非接觸式開孔機構包括低週波震盪器、高週波震盪器或烤箱。
- 如申請專利範圍第3項所述之方法,其中該前處理機構包括可實施選自電漿處理、電暈處理、紫外線照射、臭氧處理、錨定處理、膨潤處理及預熱處理所成群的至少1種或2種以上的組合之機構。
- 如申請專利範圍第1項所述之方法,其中塗佈步驟後,更包括藉由至少一組壓入滾輪,使該構成塗膜的材料滲入基材中的步驟。
- 一種塗佈機,其係用於在具有網孔的基材上形成有孔塗膜的塗佈裝置,包括:將構成塗膜的材料成為流體的塗佈裝置,用以在基材表面形成塗膜;複數傳動滾輪,連續傳遞長條狀的基材;開孔裝置,使通過該開孔裝置的基材形成連通基材的兩表面之貫穿孔,使該基材具有透氣性;其中該構成塗膜的材料為樹脂組成物,該樹脂組成物為選自聚酯、聚氨酯、聚醯胺、聚醇所成群的至少一種無規共聚物或嵌段共聚物所構成,在相變化溫度以下具有108Pa以上的楊氏模數;該具有網孔的基材為立體織物,該表面形成有孔塗膜的基材所具有的網孔的縮小率為50%以下,且根據ASTM D737的透氣率為100cfm(ft3/min)以上。
- 如申請專利範圍第10項所述之塗佈機,其中該開孔裝置包括選自接觸式開孔裝置及非接觸式開孔裝置所成群的至少1種或2種以上的組合。
- 如申請專利範圍第11項所述之塗佈機,其中該接觸式開孔裝置包括表面具有針狀結構的平板或滾輪。
- 如申請專利範圍第11項所述之塗佈機,其中該非接觸式開孔裝置包括低週波震盪器、高週波震盪器或烤箱。
- 如申請專利範圍第10項所述之塗佈機,更包括至少一組壓入滾輪,位於該構成塗膜的材料藉由該塗佈裝置形成塗膜於基材後,藉由調整該組壓入滾輪間的距離或表面溫度,使該構成塗膜的材料滲入基材中。
- 如申請專利範圍第10項所述之塗佈機,其中該塗佈裝置為一擠出機。
- 一種立體織物複合材料,其係利用如申請專利範圍第1項至第9項中任一項所述之方法製造而得或使用如申請專利範圍第10項至第15項中任一項所述之塗佈機製造而得。
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TWI703972B (zh) * | 2019-08-05 | 2020-09-11 | 江慧宜 | 肢體固定裝置 |
US11883265B2 (en) | 2020-08-19 | 2024-01-30 | National Taipei University Of Technology | Portable thermoshapable fabric composite heating device kit |
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