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CN101124359B - 不透液态水的增强的非织造防火织物、制造该织物的方法及含有该织物的防火物品 - Google Patents

不透液态水的增强的非织造防火织物、制造该织物的方法及含有该织物的防火物品 Download PDF

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Publication number
CN101124359B
CN101124359B CN2005800484719A CN200580048471A CN101124359B CN 101124359 B CN101124359 B CN 101124359B CN 2005800484719 A CN2005800484719 A CN 2005800484719A CN 200580048471 A CN200580048471 A CN 200580048471A CN 101124359 B CN101124359 B CN 101124359B
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China
Prior art keywords
fabric
fiber
enhancing
supatex fabric
supatex
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Expired - Fee Related
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CN2005800484719A
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CN101124359A (zh
Inventor
L·N·巴斯坎
W·F·克诺夫
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EIDP Inc
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EI Du Pont de Nemours and Co
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    • D04H13/00—Other non-woven fabrics
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Abstract

本发明涉及薄的增强的非织造织物，该织物包含不透液体的聚合物层、压缩的卷曲纤维网、粘合剂和增强纱。该织物在暴露于热或火焰时膨胀，并作为床垫、室内装饰品等物品的防火部分使用。

Description

不透液态水的增强的非织造防火织物、制造该织物的方法及含有该织物的防火物品
技术背景
1.发明领域
本发明涉及薄的增强的非织造织物，其包含不透液体的聚合物层、卷曲纤维压缩网、粘合剂和增强纱。该织物在暴露于热或火焰时膨胀，并作为床垫、室内装饰品等物品的防火部分使用。本发明进一步涉及加入了该织物的防火物品。本发明还涉及制备该增强非织造织物和将该织物加入至物品的方法。
2.相关技术说明
加利福尼亚州率先开始了对床垫和床垫组可燃性的调节和降低，以试图减少在家庭、旅馆和公共场所的火灾中丧失的生命。特别地，加州消费者事务部的家具及热绝缘材料办公署(the Bureau of HomeFurnishings and Thermal Insulation of the Department of Consumer Affairsofthe State of California)颁布了第603号技术公报(Technical Bulletin 603)“住宅用床垫/弹簧床垫组对大的开放火焰的耐火性的要求和检验方法”(“Requirements and Tests Procedure for Resistance of a ResidentialMattress/Box Spring Set to a Large Open-Flame”)以量化床垫组的可燃性性能。在很多情况下，床垫制造者想加入防火层，然而他们不希望该附加层有损其床垫的现有美观。
坚固的薄织物，例如短纤维和薄增强纱织物(scrim fabric)的结合，在很多情况下可能会需要，因为它们经久耐用并且不太可能令人反感。本领域中已知多种方法，可用于将短纤维与将短纤维锁定在适当位置的纱织物相结合。所述方法的其中一种为水缠结，在多种出版物上也被称为hydrolacing、射流喷网和水射流处理，其中高压水流冲击所述短纤维并将之加入纱中，以使纤维和纱加固至一起。本领域另一已知的合并短纤维和纱织物的方法为针刺法。在该方法中，钩针钩住短纤维并将之加入纱中或内纤维絮中，以使该结构锁定至一起。由这些方法制备的非织造布机械地、坚固地使该短纤维自身缠结，或用纱将其缠结或二者兼有，限制了该织物在加热或暴露于火焰时膨胀的能力。
本领域另一已知的合并短纤维和纱织物的方法为粘性层压或添加粘合剂。在该方法中，用粘合剂或粘胶将层或单纤维粘合或结合至一起。例如，Erb的美国专利第6579396号和6383623号以及Yamaguchi等的欧洲专利EP622332均公开了利用粘合剂维持所述厚织物的蓬松度或厚度；即，该非织造织物保持蓬松的或膨胀的形态并因此具有弹力。
除了需要坚固薄织品用于防火之外，在很多情况下，需要保护床垫或其他带垫套的物品的内部免受体液或其他含水液体的损害。因此，需要一种既能防火又能防液体的薄增强织物。
发明概述
本发明涉及用于物品防火的增强的非织造织物，和包含该织物的物品，所述增强非织造织物包含不透液态水的聚合物层和具有第一侧和第二侧的开放网眼纱，所述纱的第一侧具有卷曲和耐热的有机纤维，该纤维压缩于其上并由热塑性粘合剂将其保持为压缩状态，其中，当该织物暴露于热或火焰时，该织物可以将其厚度增加至至少两倍。
本发明还涉及制造该增强非织造织物的方法，该织物在暴露于热或火焰时膨胀以用于物品的防火，所述方法包括步骤：
a)形成包含卷曲的耐热有机纤维和粘合剂纤维的第一纤维网，
b)将该纤维网与开放网眼纱的第一侧接触以形成织物组件，所述纱具有第一侧和第二侧，
c)将粘合剂粉末应用于该织物组件，
d)将所述纤维网与聚合物薄膜接触，
e)加热所述织物组件和聚合物薄膜，以活化粘合剂纤维与粘合剂粉末，并软化聚合物薄膜，
f)将所述织物组件压缩至压缩状态，其中，将该聚合物薄膜层压至该纤维网，和
g)在压缩状态下冷却所述织物组件，以形成增强的非织造织物。
发明详述
本发明涉及用于物品防火的、含水液体不能渗透的薄增强非织造织物，并且当遇热或火焰时，该织物能够将其厚度增加至原厚度的至少两倍。该织物包含具有第一侧和第二侧的开放网眼纱，所述第一侧具有卷曲和耐热的有机纤维，该纤维压缩于其上并由热塑性粘合剂保持为压缩状态。当该织物遭受高温或火焰时，其结构中的粘合剂软化，释放出被抑制的卷曲纤维并容许所述织物的厚度大大地增加。这种增加在织物中产生气穴，被认为能够提高该织物的热性能。
该织物在应对高温或火焰时能够增加其厚度，因为该卷曲耐热有机纤维虽为压缩的，但在织物中并没有明显缠结。以往开发出的纤维纱布专注于确保纤维与纱和/或与布中的其他纤维的高水平的机械缠结。典型地，该机械缠结是通过向形成布的蓬松的纤维网和/或纱施加能量以使该纤维缠结并使该布变稠密来达到的。当完成该步骤时，布中纤维的缠结程度使之在遇到热和火焰时不能自由移动。
本发明织物的纤维具有刚刚足够制造所述布的缠结程度；即，所述纤维之间的缠结刚刚达到形成能覆盖或结合于开放网眼纱的轻质纤维网所需的程度。没有使纤维互相缠结或与该纱缠结的附加能量施加至该布。然后，将轻质纤维网层压至纱，其方法为加热和压缩该组合然后冷却该组合以构成该结构，而卷曲纤维为被压缩和抑制的状态。通过这种方法压缩蓬松布，当粘合剂材料软化时，该布中的纤维可以自由地恢复形式上蓬松的状态，即类似于压缩前的状态。
本发明的织物还含有不透液态水的聚合物层以防止含水液体穿透该织物。如果该织物包含一层卷曲纤维网，该薄膜则优选地覆盖于该网之上，但是它也可以覆盖于纱的与该网相对的第二侧之上。然而优选地，该织物在纱的第一侧和第二侧上各包含至少一层纤维网，并且该聚合物层覆盖于所述轻质纤维网之一上。在各种情况下，均提供了具有不透液态水的聚合物层作为一个外表面的织物。
本发明的增强的非织造织物优选地具有约40至260g/m2(1.2至7.7oz/yd2)的总单位重量。这种织物还优选地具有约0.026至0.25厘米(0.010至0.10英寸)的总厚度。仅包含轻质纤维网和纱的组合，当被压缩时，优选地具有0.025至0.24厘米(0.010至0.10英寸)的厚度并且还优选地具有范围在20至170g/m2(0.6至5oz/yd2)的单位重量，其中纱组分优选地占有3.4至34g/m2(0.1至1.0oz/yd2)且纤维网组分的范围优选为17至136g/m2(0.5至4.0oz/yd2)。该聚合物层优选地具有0.012至0.076毫米(0.0005至0.003英寸)的厚度。对于用于本发明的许多聚合物，所述厚度对应于，聚合物层具有优选约20至90g/m2(0.6至2.7oz/yd2)的单位重量，优选29至85g/m2(0.84至2.55oz/yd2)。
本发明的增强的织物在遇高温或火焰时，其总厚度增加至原厚度的至少两倍，并优选地增加至原厚度的三倍。低至150℃的温度被认为是引发该膨胀效果的所需温度，并且认为从约225℃的温度开始，该膨胀作用立即发生。认为当该织物直接遭遇火焰时其体积膨胀达到最大量。
本发明的增强的非织造织物包含不透液态水的聚合物层。“不透液态水”指的是若含水液体释放或洒至该织物上，该液体将不会从该织物的一边渗入至另一边。液态水应包括任何量的通常可能会洒到或释放到床垫或有垫套的家具上的含水液体。这样的含水液体还应包括除水之外的液体，例如饮料(例如苏打饮料和果汁)以及体液(例如尿液)。
该聚合物层优选为一薄层聚合物，例如连续膜，然而若需要，可以使用聚合物的连续涂层。任何对于该织物中用到的轻质纤维网或热塑性粘合剂具有足够粘性的持久耐用的聚合物或聚合物的组合均可使用。发明人发现，聚氨酯薄膜以其耐久性为优选的聚合物层。或者，燃烧时会释放出抑制火焰的气体的卤化聚合物薄膜，例如聚氯乙烯薄膜，需要时可以使用。
优选地，该聚合物层与卷曲耐热纤维的轻质纤维网相接触并粘合，并且优选地形成该增强织物的一层外表面。该聚合物层非常轻质并仅仅具有0.012至0.076毫米(0.0005至0.003英寸)的厚度。优选地，该聚合物层的添加不明显改变其下的纤维网与纱的组合的柔韧性，使整个织物的柔韧性和织物特性与不含有该聚合物层的压缩的非织造织物基本相同。
该聚合物层在织物上形成连续液体屏障。该聚合物层优选地粘附于纤维网的整个表面。也就是说，当该聚合物层施用于该纤维网和/或纱时，无论是通过加热和软化薄膜的表面施用，或是通过将纤维网和/或纱与粘性聚合物涂层相接触施用，该聚合物层均优选地附着于所述纤维的大部分，即该聚合物层与纤维网的整个表面相接触。
本发明的增强的非织造织物包含卷曲耐热有机纤维。该卷曲纤维优选为短纤维，所述短纤维的切割长度在0.4至2.5英寸(1至6.3厘米)范围，优选0.75至2英寸(1.9至5.1厘米)并优选地具有2至5卷曲/厘米(5至12卷曲/英寸)。“耐热纤维”指的是在以20℃/分钟的速度在空气中加热至500℃时，该纤维优选地保持其纤维重量的90％。这种纤维通常为耐火焰的，指的是该纤维或由该纤维制成的织物具有极限氧指数(LOI)，使该纤维或织物不支持空气中火焰，优选的LOI范围为约26及更高。优选的纤维在暴露于火焰时不会过度收缩，即在暴露于火焰时该纤维的长度不会显著地缩短。包含在以20℃/分钟的速度在空气中加热至500℃时能保持其纤维重量90％的有机纤维的织物在被碰撞火焰灼烧时往往仅具有少量的裂缝和开口，这对该织物的防火性能是很重要的。
本发明的增强的非织造防火织物中有用的耐热短纤维包括由对-芳族聚酰胺、聚氮茚、聚苯并咪唑或聚酰亚胺制备的纤维。优选的耐热纤维由芳族聚酰胺聚合物制备，尤其是对-芳族聚酰胺聚合物。
按照此处的应用，“芳族聚酰胺”指的是聚酰胺，所述聚酰胺中至少85％的酰胺键(-CONH-)与两个芳环直接相连。“对-芳族聚酰胺”指的是两个环或基团以相对于彼此为对位取代的方式存在于分子链上。添加物可以与芳族聚酰胺一同使用。事实上，现已发现，多达10％重量的其他聚合物材料可以与芳族聚酰胺共混，或可以使用共聚物，所述共聚物具有10％的其他二胺，用以代替芳族聚酰胺的二胺，或具有10％的其他二酰基氯，用以代替芳族聚酰胺的二酰基氯。本发明的实施中，优选的对芳族聚酰胺为聚对苯二甲酰对苯二胺。制备本发明中有用的对-芳族聚酰胺纤维的方法在以美国专利第3869430、3869429和3767756号为例的专利中有大致性的公开。该芳香聚酰胺有机纤维以及该纤维的多种形式是商标为的可得自DuPont Company，Wilmington，Delaware的商品。
本发明应用的市售聚氮茚纤维包括可购自Toyobo，Japan的
Figure G2005800484719D00062
PBO-AS(聚对亚苯基-2，6-苯并双噁唑)纤维、
Figure G2005800484719D00063
PBO-HM(聚对亚苯基-2，6-苯并双噁唑)纤维。本发明应用的市售聚苯并咪唑纤维包括购自Celanese Acetate LLC的
Figure G2005800484719D00064
纤维。本发明应用的市售聚酰亚胺纤维包括购自LaPlace Chemical的纤维。
或者，“耐热纤维”可以包括在以20℃/分钟的速度在空气中加热至700℃时保持其纤维重量至少10％的纤维素纤维。该纤维被认为是成炭的。具有10％或更多的无机化合物加入至纤维中的再生纤维素纤维为优选的纤维素纤维。该纤维，以及制备该纤维的方法，大致公开于美国专利第3565749号和英国专利第1064271号。本发明优选的成炭再生纤维素纤维为含有含水二氧化硅的粘胶纤维，所述含水二氧化硅以带有硅酸铝位点的聚硅酸形式存在。该纤维，和制备该纤维的方法，大致公开于美国专利第5417752号和PCT专利申请WO9217629。包含硅酸并具有大约31(±3)％无机材料的粘胶纤维，是商标为
Figure G2005800484719D00071
的购自Sateri Oy Company of Finland的市售商品。
该耐热纤维可以与其他纤维共混，然而，优选地，其他纤维不应破坏该织物的防火能力。例如，多达50％的改性聚丙烯酸纤维(modacrylic)可以与该耐热纤维共混。改性聚丙烯酸纤维是有用的，因为该纤维在灼烧时会释放出抑制火焰的含卤素的气体。“改性聚丙烯酸纤维”指的是由包含丙烯腈的聚合物制备的丙烯酸合成纤维。所述聚合物优选为含有30-70％重量的丙烯腈和70-30％重量的含卤素的乙烯基单体的共聚物。所述含卤素的乙烯基单体为选自下述的至少一种单体，例如氯乙烯、偏氯乙烯、溴乙烯、偏溴乙烯，等等。可共聚的乙烯基单体的例子为丙烯酸、甲基丙烯酸、上述酸的盐或酯、丙烯酰胺、甲基丙烯酰胺、乙酸乙烯酯，等等。
本发明优选的改性聚丙烯酸纤维为丙烯腈与偏氯乙烯结合的共聚物，而且该共聚物可附加地含有一种或多种氧化锑以改进其阻燃性。该有用的改性聚丙烯酸纤维包括但并不局限于美国专利第3193602号公开的含有2％重量的三氧化二锑的纤维、美国专利第3748302号公开的与至少2％重量并优选不高于8％重量的多种锑氧化物制成的纤维，以及美国专利第5208105和第5506042号公开的具有8-40％重量的锑化合物的纤维。优选的改性聚丙烯酸纤维为购自日本KanekaCorporation的市售商品，例如他们的据称包含10-15％重量的锑氧化物的Protex C纤维；或含有更少量锑氧化物的其他纤维，即含量范围为6％重量或更少；或不含有锑氧化物的纤维也可使用。
该卷曲有机纤维优选地用多达30重量份的粘合剂材料保持在适当位置。优选的粘合剂材料为当施与热时能够被活化的粘合剂纤维和粘合剂粉末的组合。粘合剂纤维通常由热塑性材料制备，所述热塑性材料具有比纤维共混物中任何其他短纤维更低的软化点。鞘/芯双组分纤维为优选的粘合剂纤维，尤其是具有聚酯均聚物芯和作为粘合剂材料的共聚酯的鞘的双组分粘合剂纤维，例如可购自日本Unitika Co.的市售商品(例如，商标为
Figure G2005800484719D00081
)。有用的粘合剂纤维的类型还可包括由聚酰胺制备的纤维，例如Griltex PA Biko BA 140 8 dpf，切割长度2英寸的尼龙粘合剂纤维；或由聚丙烯、聚乙烯、或聚酯聚合物或共聚物制备的粘合剂纤维，该纤维只包含所述聚合物或共聚物，或为具有并行或鞘/芯构造的双组分纤维。该粘合剂纤维优选地以多达该增强的非织造织物的20％的量存在。粉末粘合剂优选地以多达该增强的非织造织物的30％的量存在。该优选的粘合剂粉末为热塑性粘合剂粉末，例如共聚酯Griltex EMS 6E粘性粉末或Gnlon SMS D1260 Aft62聚酰胺(尼龙)粉末。
本发明的增强的非织造织物还包含开放网眼纱。该纱优选地具有范围为3.4-34g/m2(0.1-1.0oz/yd2)的单位重量，并且“开放网眼”纱的称谓源于所述纱在经向和纬向仅具有约0.8-6根纱/厘米(2-15根纱/英寸)。最优选的开放网眼纱具有范围为6.8-24g/m2(0.2-0.7oz/yd2)的单位重量，并优选地在经向和纬向具有1-4根纱/厘米(3-10根纱/英寸)。通常地，该网眼纱是通过将两套斜交聚酯连续长丝或具有粘合剂涂层的连续长丝纱粘合至一起而制备的。在某些纱中，在任何一个方向的纱，比方说纬向的纱，可以由在横向经纱的任一侧或两侧按需要设置的多个连续长丝组成。代表性的开放网眼纱是商标为
Figure G2005800484719D00082
Scrim Fabrics的购自Saint-Gobain Technical Fabrics of Niagara Falls，New York的市售商品。在本发明的增强的非织造织物中尤其适用的开放网眼纱为Saint-Gobain 2.7×2.7纱(型号QV3311/A31)，该纱在其纬向具有2.7根经纱/英寸的500旦尼尔聚酯，并在其经向具有2.7根纱/英寸的500旦尼尔聚酯。其具有14.2g/m2(0.42oz/yd2)的公称单位重量。该类型的纱提供了足够的强度，同时不会过多地增加其可燃性。该开放网眼还被认为在该织物暴露于高温时有助于织物中开放气穴的形成，这是因为由于与纤维网之间结合点的数量很少，网眼纱应约束更少的耐热纤维。该纱可以含有热塑性或非热塑性长丝，可为芳族聚酰胺、尼龙、玻璃或聚酯。若该纱为热塑性的(例如聚酯)，当灼烧该非织造织物时，在卷曲耐热纤维膨胀的同时，所述网眼在灼烧区域基本消失。
制备本发明的不透液体的增强的非织造织物的优选的方法，优选地应用轻质薄膜作为聚合物层。这样的增强织物可以由包含下述步骤的方法制备：
a)形成包含卷曲的耐热有机纤维和粘合剂纤维的第一纤维网，
b)将该纤维网与开放网眼纱的第一侧接触以形成织物组件，所述纱具有第一侧和第二侧，
c)将粘合剂粉末应用于该织物组件，
d)将所述纤维网与聚合物薄膜接触，
e)加热所述织物组件和聚合物薄膜，以活化粘合剂纤维与粘合剂粉末，并软化聚合物薄膜，
f)将所述织物组件压缩至压缩状态，其中，将该聚合物薄膜层压至该纤维网，和
g)在压缩状态下冷却所述织物组件，以形成增强的非织造织物。
所述纤维网可以由任何能生成低密度纤维网的方法制备。例如，卷曲短纤维束和由纤维包获得的粘合剂纤维可以通过以清棉机为例的设备打开。优选地，该纤维为短纤维，所述短纤维具有约0.55至约110dtex/长丝(0.5-100旦尼尔/长丝)的线密度，优选0.88-56 dtex/长丝(0.8-50旦尼尔/长丝)，最优选约1-33dtex/长丝(0.9-30旦尼尔/长丝)的线密度。
打开的纤维混合物随后可以由任何可行方法进行共混，例如气力输送，以生成更均一的混合物。或者，可以在清棉机中打开纤维之前，将该纤维进行共混以生成更均一的混合物。然后可以运用以梳理机为例的设备将该纤维共混物转变为纤维网(虽然其他方法，例如纤维的气流成网也可适用)。优选地直接应用从梳理机中得到的纤维网，而不需任何交叉铺网。然而若需要，该纤维网可以随后由输送机输入至以交叉铺网机为例的设备中，通过按锯齿结构在单层纤维网上面层加另一层纤维网的方法生成交叉铺网式的纤维网。
来自一个或多个梳理机的纤维网，以及开放网眼纱，可以随后收集至传输带上。优选地，该方法在步骤c)之前有附加步骤，即将开放网眼纱的第二侧与含有耐热有机纤维和粘合剂纤维的第二纤维网接触。通常，将该纱插入至两层纤维网之间以生成双层或多层网结构，或织物组件(fabric assembly)。若需要，可以将附加纤维网铺设至两层纤维网的任一层上。然后将粘合剂粉末以优选为约3.4至24g/m2(0.1至0.7oz/yd2)的量应用至合并的纤维网和纱(所述织物组件)。
然后可通过将聚合物薄膜置于最上层纤维网的顶表面上而将该薄膜覆盖于该织物组件上。然后将合并的薄膜、纤维网、粘合剂粉末和纱输送穿过烘箱，该烘箱的温度足够使粘合剂纤维和粉末软化并活化，使其将纤维粘合至一起，并也软化该聚合物薄膜以使薄膜粘附于与之接触的纤维。在烘箱出口处，该薄片(sheet)优选地在两个钢辊间压缩，以将多个层加固为粘合的织物。然后该织物优选地在该压缩状态下冷却。
本发明的增强的非织造织物可随后以防火的目的加入至物品中，例如家具，或优选地，床垫和床托组合。使床垫防火的一个方法是将床垫芯的面板与边缘用本发明织物完全覆盖，并在接缝处将该织物缝合至一起以密封该床垫。这将保证无论哪个面板或边缘暴露于火焰，该床垫均为防火的。
床托，例如弹簧床垫，通常不需要完全防火，但通常仅要求其边缘为防火的，而防火性质对于床托的上表面或面板来说为任选的。然而，本发明的增强的非织造织物，可按需要应用于床托边缘或面板。
该增强的非织造织物被认为可以为不能通过2003年7月颁布的加州第603号技术公报(California Technical Bulletin 603)的物品提供足够的防火性质，以使该物品能通过2003年7月颁布的加州第603号技术公报(California Technical Bulletin 603)，而不需添加任何化学阻燃材料。该增强的非织造织物可以加入至物品中，例如床垫，所述加入方式可以为能使该床垫通过其原本不能通过的测试的任何方式。
测试方法
热重分析法。本发明应用的织物在以特定的加热速度加热至高温时保留其纤维重量的一部分。该纤维重量由得自TA Instruments(Waters Corporation的分公司)，Newark，Delaware的2950型热重分析仪(TGA)测定。该TGA提供对于温度升高引起的样品重量减少的扫描。运用TA Universal Analysis程序，可在任何记录的温度下测量重量减少的百分数。该程序大体情况包含，在50℃平衡该样品；以10或20℃/分钟的速度将温度由50℃缓慢升高至1000℃；利用空气为气体并以10ml/分钟提供；并利用500微升陶瓷杯(PN 952018.910)为样品容器。
该测试方法如下。利用TA Systems 2900 Controller上的TGA屏幕对TGA进行编程。输入样品ID，并选定20℃/分钟的缓慢加温程序。利用该仪器的“定皮重”功能确定空样品杯的皮重。纤维样品被切割至大约1/16″(0.16cm)的长度，并将该样品松散地填充至样品盘。样品重量应该在10至50mg的范围内。该TGA具有天平，因此确切重量不需要提前测定。样品盘之外不应有样品。将填充好的样品盘装载至中线(balance wire)上，并确保热电偶靠近该盘的上边缘而不与之接触。将炉在该盘的上方提升，并启动该TGA。一旦程序完成，该TGA将自动降低炉，移去样品盘并进入冷却模式。随后利用TA System 2900Universal Analysis程序分析并生成在温度变化范围内重量减少百分数的TGA扫描。
热性能温度。该织物在高温下和热流下的绝热性质通过运用与建筑灭火防护系综NFPA1971标准(NFPA1971 Standard on ProtectiveEnsemble for structural Fire Fighting)2000版6-10节中所用相同的仪器测量。为了表征本发明的材料，该仪器在数据获取模式下操作。将2cal/cm2/秒(8.38J/cm2/秒)的热流施加于该织物90秒。与此同时，穿过材料的热量由热量计测量，所述热量计直接与样品的背面(基层)接触。以暴露90秒后热量计热电偶的温度对该材料进行表征。该数值与穿过织物的热量成正比。
单位重量。该织物的单位重量用ASTM D6242-98测定。
实施例1
增强的非织造织物的制备如下。将42.5重量份的2.2dpf、2″切割长度的970型
Figure G2005800484719D00121
牌短纤维，42.5重量份的3.5dpf、2″切割长度的
Figure G2005800484719D00122
33AP短纤维和10重量份的4dpf、2″切割长度的4080型Unitika粘合剂纤维共混，并由纤维包进料至三个梳理机中。将三个梳理机的纤维网收集在传输带上，以生成单位重量为大约2.2oz/yd2的纤维网。将聚酯长丝纱的开放网眼纱插入至由前两个梳理机形成的两层纤维网之间。该开放网眼纱为Saint Gobain 2.7×2.7纱(QV3311/A31型，在纬向具有2.7根纱/英寸的500旦尼尔聚酯，并在经向具有2.7根纱/英寸的500旦尼尔聚酯)，并且具有0.42oz/yd2的单位重量。所得的结构在开放网眼纱的一侧上具有两层疏理的纤维网，在该纱的另一侧上具有一层疏理的纤维网。
将Griltex EMS 6E 125-130C粘性粉末应用于合并的纤维网和纱，所述粘性粉末的用量使总的薄片重量为3.1oz/yd2。将来自DeerfieldUrethanes的1mil厚的聚氨酯薄膜(具有黑色颜料包的PT6100聚合物)与该纱、粘合剂粉末和纤维网合并。将该结构输送穿过285℃的烘箱以熔化该粘合剂纤维和粉末。在烘箱出口处，该薄片被两个间隙为0″的钢辊压缩，将多个组成部分加固为粘合的织物。然后将该织物在压缩状态下冷却。该织物的最终成份为大约25％
Figure G2005800484719D00123
纤维、25％
Figure G2005800484719D00124
纤维、9％粘合剂纤维、8％粘合剂粉末、11％聚酯纱和22％聚氨酯薄膜。产生的织物的热性能温度(TPT)为351℃。
实施例2
从实施例1的织物截取两个大小约为5×5厘米(2英寸×2英寸)的方形样品。用尺对该样品进行测量，其平均厚度为大约1毫米。将该样品放置于在大气压力下操作的、温度为200℃的烘箱中5分钟。将样品从烘箱取出并冷却。再次用尺测量该样品，发现其平均厚度增加至4毫米。样品厚度的增加，没有造成织物明显的平面收缩，然而其聚合物膜层有一些损坏。样品厚度的平均增量大约为增至样品原厚度的4倍。
实施例3
将实施例1的织物样品按照实施例2的方法在烘箱中加热，然而，将各样品加热至不同温度并记录样品膨胀所需的时间。然后将样品在烘箱中放置20分钟，从烘箱中取出，并记录薄膜的状态。最后，用尺测量膨胀样品的厚度。该样品厚度的增加为，在150℃时增至2.5倍，在250℃时增至4.5倍，织物没有出现明显的平面收缩。结果总结于表1。
表1
  温度(℃)   时间(分钟)   厚度(毫米)   膨胀所需时间(秒)   PU薄膜
  未处理   --   1    --
  150   20   2.5   60   完好
  175   20   3   30   完好
  200   20   4   10   部分熔化
  230   20   4   立即   部分熔化
  250   20   4.5   立即   部分熔化

Claims (22)

1.一种用于物品防火的增强的非织造织物，该织物包含不透液态水的聚合物层和具有第一侧和第二侧的开放网眼纱，该纱的第一侧具有卷曲和耐热的有机纤维，该纤维压缩于其上，并由热塑性粘合剂保持为压缩状态，
其中，当该织物暴露于热或火焰时，该织物能够将其厚度增加至原厚度的至少两倍。
2.权利要求1的增强的非织造织物，其中该织物在暴露于热或火焰时能够将其厚度增至原厚度的三倍。
3.权利要求1的增强的非织造织物，该织物进一步包含压缩于所述纱的第二侧上的卷曲和耐热的有机纤维，该纤维由热塑性粘合剂保持为压缩状态。
4.权利要求1的增强的非织造织物，其中所述聚合物层为薄膜。
5.权利要求1的增强的非织造织物，其中所述聚合物层为涂层。
6.权利要求1的增强的非织造织物，其中所述聚合物层包含聚氨酯聚合物。
7.权利要求1的增强的非织造织物，其中所述聚合物层包含聚氯乙烯聚合物。
8.权利要求1的增强的非织造织物，其中所述聚合物层的厚度为0.0005至0.003英寸。
9.权利要求1的增强的非织造织物，其中所述耐热有机纤维为对-芳族聚酰胺纤维。
10.权利要求9的增强的非织造织物，其中所述对芳族聚酰胺纤维为聚对苯二甲酰对苯二胺。
11.权利要求1的增强的非织造织物，其中所述耐热有机纤维由选自聚氮茚、聚苯并咪唑和聚酰亚胺的聚合物制成。
12.权利要求1的增强的非织造织物，其中所述耐热有机纤维为纤维素纤维，该纤维素纤维在空气中以20℃/分钟的速度加热至700℃时保留其纤维重量的至少百分之十。
13.权利要求12的增强的非织造织物，其中所述纤维素纤维为含有含水二氧化硅的粘胶纤维，该含水二氧化硅为带有硅酸铝位点的聚硅酸形式。
14.权利要求1的增强的非织造织物，其中所述耐热有机纤维与多达50％重量的改性聚丙烯酸纤维共混。
15.权利要求1的增强的非织造织物，其中所述热塑性粘合剂包含粘合剂纤维。
16.权利要求1的增强的非织造织物，其中所述热塑性粘合剂包含粘合剂纤维与粘合剂粉末的组合。
17.权利要求1的增强的非织造织物，其中所述开放网眼纱包含热塑性材料。
18.一种防火物品，所述物品包含权利要求1的增强的非织造织物。
19.一种防火床垫，所述床垫包含权利要求1的增强的非织造织物。
20.一种防火的有垫套的家具，所述家具包含权利要求1的增强的非织造织物。
21.一种制造增强的非织造织物的方法，该织物在热或火焰中膨胀，以用于物品的防火，所述方法包括以下步骤：
a)形成包含卷曲的耐热有机纤维和粘合剂纤维的第一纤维网，
b)将该纤维网与开放网眼纱的第一侧接触以形成织物组件，所述纱具有第一侧和第二侧，
c)将粘合剂粉末应用于该织物组件，
d)将所述纤维网与聚合物薄膜接触，
e)加热所述织物组件和聚合物薄膜，以活化粘合剂纤维与粘合剂粉末，并软化聚合物薄膜，
f)将所述织物组件压缩成压缩状态，其中，将所述聚合物薄膜层压至该纤维网，和
g)在压缩状态下冷却所述织物组件，以形成增强的非织造织物。
22.权利要求21的方法，所述方法在步骤c)前具有附加步骤，将开放网眼纱的第二侧与含有耐热有机纤维和粘合剂纤维的第二纤维网接触。
CN2005800484719A 2004-12-27 2005-12-27 不透液态水的增强的非织造防火织物、制造该织物的方法及含有该织物的防火物品 Expired - Fee Related CN101124359B (zh)

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