CN1717324B - 防渗透织物 - Google Patents

防渗透织物 Download PDF

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Publication number
CN1717324B
CN1717324B CN2003801044628A CN200380104462A CN1717324B CN 1717324 B CN1717324 B CN 1717324B CN 2003801044628 A CN2003801044628 A CN 2003801044628A CN 200380104462 A CN200380104462 A CN 200380104462A CN 1717324 B CN1717324 B CN 1717324B
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CN
China
Prior art keywords
fabric
barrier
fabric according
adhesive
place
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CN2003801044628A
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English (en)
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CN1717324A (zh
Inventor
R·P·迪蒙特
W·C·金佰利
T·E·高德弗里
S·J·林
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sage Vehicle Interior Ltd By Share Ltd
Original Assignee
Milliken and Co
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Publication date
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Publication of CN1717324A publication Critical patent/CN1717324A/zh
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Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/02—Layered products comprising a layer of synthetic resin in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/58—Seat coverings
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
    • D06N3/183—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials the layers are one next to the other
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2255/26—Polymeric coating
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
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    • Y10T442/2066—Different coatings or impregnations on opposite faces of the fabric
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Abstract

本发明提供了独特地结合了防污性、防流体渗透性能、美观特性和悬垂性的织物，和制造此织物的一种方法。该织物含有用低表面能防污化合物处理至少一个表面的织物基层，和固定于其另一个表面的一层或更多层，这些层为该织物提供了独特结合的特性。此外，该织物理想地提供了阻燃性和防紫外辐射特性，从而使其能够用作运输工具的座椅材料。本发明还说明了制造该织物的方法。

Description

防渗透织物
技术领域
本发明涉及一种防渗透织物。更具体地，本发明涉及独特地结合了防污性、防流体渗透性能、美观特性和悬垂性的织物。
背景技术
迄今为止，已经有大量的方法用来制造可清洁的和耐液体的织物，以便使其在可能发生液体沾污的环境中更加有用。乙烯基涂层织物由于相对易清洁和相当低的成本而被最广泛地应用于这些用途中。这些织物一般通过在稀松型织物(open scrim-type fabric)上应用乙烯基涂层而制造，且该乙烯基表面形成外表面或与使用者接触的表面。然而，此乙烯基涂层织物一般触摸起来有点硬，因此缺少某些使用环境所期望的外观和触感，这些环境是例如汽车、餐馆、疗养院、和类似的需要令使用者的触觉和视觉满意的环境。此外，乙烯基能够令使用者的皮肤不舒服，并且由于它形成一个连续的、不透气的表面，它能引起使用者与座椅之间汗水的积聚。此外，乙烯基表面可以变得非常热，并且不舒适或者甚至在一些情况下坐在上面会感到痛苦。
表面层压织物已被用于增强织物的美观性，但是由于一般在层压膜与织物本身之间的分离性粘合，这些产品在长期使用后趋于剥离、开裂、和脱层。这样的层压产品也缺乏标准的室内装饰物一般期望的触感。此外，当应用氟化物防污处理剂时，防液体渗透膜或涂层对织物基层的粘合更困难，因为此组合物本质上趋于排斥所应用的涂层。
在克服上述现有技术材料的许多缺点的同时，已发现用目前方法生产的织物的柔韧性和可挠性未达到一些最终应用的最佳化要求，尤其是例如复杂形状的运输工具座椅构造或类似物的应用。(尽管以上说明在一定程度上涉及汽车和卡车，本文所用的术语“运输工具座椅”是要包括所有类型交通工具的座椅或者其它表面区域，这些交通工具包括但不限于船、飞机、直升机、自行车和摩托车、火车、例如拖拉机、推土机的机械、和类似物)。
为获得具有一些上述所需特性的织物，已经开发的一种方法在由DeMott等人于2001年5月23日提交的共同转让、共同未决的美国专利申请第09/864,461号中说明，该申请是于2000年7月25日提交的共同未决的美国专利申请第09/625,474号的部分继续，美国专利申请第09/625,474号是于1999年4月6日提交的美国专利申请第09/286,797号，并于2000年10月24日授权给Kimbrell，Jr.等人的美国专利第6,136,730号的继续，美国专利第6,136,730号是于1997年2月12日提交的美国专利申请第08/799,790号，并于1999年5月4日授权给Kimbrell，Jr.等人的美国专利第5,899,783号的部分继续。这些文献全部在本文引入作为参考。
然而，对于可清洁的和耐液体的织物，仍然需要具有好的耐火性能而使它们能够用于例如运输工具的应用中，并且具有好的美观性，包括好的柔韧性。
发明内容
根据前面所述，本发明的一个目的是提供能够用于运输工具的织物，该织物具有满足家庭型运输工具各种需要的令人满意的美观性，并具有传统的运动型多功能车一般要求的耐用性、以及防污和防水性，同时理想地具有耐燃性和防紫外辐射能力。
本发明的另一个目的是提供具有防污和防流体渗透性能的织物，但是该织物还像传统未处理的室内装饰织物一样表现出好的悬垂性能，这里好的悬垂性被认为是织物具有平均的柔韧性和/或缺乏硬度。
本发明还有一个目的是提供一种制造具有上述性能的织物的经济和有效方法。
为了这个目的，本发明提供了独特地结合了防污和防流体渗透性能的织物，同时该织物的悬垂性更加可比于传统未处理的织物。这样，该织物不仅在用于制成占用者支撑表面时是舒适的，而且该织物还能够用于例如复杂形状的座椅构造的应用中。此外，该织物还理想地具有高度的防紫外辐射能力和耐燃性，并且与传统的座椅泡沫材料形成好的结合，从而使该织物特别有利于制造汽车座椅。
此外，该织物能够接受例如抗静电剂、抗菌剂等其它附加材料，以提供所期望的附加性能特性。该织物可以通过以下方式制造：提供用低表面能防污化合物处理的纺织织物基层，并对该织物基层应用至少一层，优选两层或更多层材料，使得该材料层连同织物基层提供一种织物，当根据ASTM D751(2001)检测时，该织物具有的结合强度至少约为3792.25Pa(0.55lbs/in2)，并且优选约6895Pa(1lbs/in2)或更大，耐静压(hydrostatic pressure resistance)至少约为5000Pa(50mb)，并且更优选至少约10000Pa(100mb)，当根据AATCC检测方法118-1997检测时，油级(oil rating)约为3或更大。优选地，通过SAE J1885MAR92测定，该织物还具有低于10.16cm(4英寸)的燃烧速率，和在225kj大约4.0或更小的ΔE(证明其具有好的防紫外辐射能力)。
在该方法的一个实施方式中，在织物的至少一个表面提供了低表而能防污化合物，并在其另一表而应用例如丙烯酸材料的稳定材料。将粘合剂材料应用于该稳定材料，该粘合剂材料又用于将防渗透材料结合到该结构上。在另一个实施方式中，省略了稳定层，并将FR添加剂引入防渗透材料和/或粘合剂材料中，从而使该织物能够达到汽车工业的燃烧标准。
具体实施方式
在本发明的以下详细说明中，描述了本发明特定优选的方案，从而能够充分和完全地理解本发明。应该明白这不是为了将本发明限制于说明的特别优选的实施方式中，而且虽然在说明该发明时使用了特定术语，但是这些术语具有描述性意义并用于说明目的，不是为了限制。
本发明通过提供具有纺织织物的触感和悬垂性(由柔韧性/可挠性为指标)的织物，克服了传统织物的缺点，同时该织物具有好的可清洁性、防流体渗透特性、耐火特性和耐用性。此外，本发明说明了一种制造此织物的有效和经济的方法。另外，生产出的本发明的织物能够包括例如防紫外、抗菌等的附加特性。
本发明的织物理想地具有用例如氟化物的低表面能防污化合物化学处理的织物基层，和一个或更多附加层，使该织物独特地结合了可清洁性、防流体渗透特性、耐火性、柔韧性和耐用性。在本发明的一个实施方式中，该织物还具有防紫外辐射能力。优选地，该织物有好的可清洁性，当根据AATCC检测方法118-1997测试时，油级至少约为3或更大，当根据AATCC检测方法127-1998测试时，耐静压约为50或更大，并优选约100或更大，当根据FMVSS-302(联邦汽车安全标准，Federal Motor Vehicle Safety Standard)测试时，燃烧速率低于约4in/min，并且当根据ASTM D751测试时，结合强度约为3792.25Pa(0.55lbs/in2)或更大。此应用中特别优选的织物具有大约4或更大的油级，并且更优选约为5。
如所指出的，该织物理想地具有好的防流体渗透特性。为了这个目的，当根据AATCC检测方法127-1998测试时，该织物理想地具有至少约5000Pa(50mb)的静水压，并且更优选大约10000Pa(100mb)或更大，进一步优选大约12500Pa(125mb)或更大，更进一步优选大约15000Pa(150mb)或更大。在本发明的一个特别优选的实施方式中，该织物的抗流体静力约为200或更大的。此外，当根据AATCC检测方法22-1996测试时，该织物理想地具有至少约70的沾水等级，并且更优选至少约75，进一步优选至少约80。这样，该织物能够在最终应用中很好地起作用，该最终应用例如上述混合运输工具的汽车座椅，由于这种织物会抵御溢出物，在与污垢、食物、或类似物接触时能够被冲洗。
在本发明的另一方面中，该织物在用于例如汽车内饰时，理想地具有好的耐燃特性。目前的政府标准规定，用于汽车内饰应用材料的燃烧速率应低于每分钟10.16cm(4英寸)。根据本发明制造的织物能够被生产出而达到，甚至超过这个耐火标准。在本发明的一个实施方式中，该织物在每一纵向和横向的燃烧率小于每分钟10.16cm(4英寸)，更优选在每个方向小于约每分钟7.62cm(3英寸)，进一步优选在每个方向小于每分钟5.08cm(2英寸)。同样在本发明的实施方式中，能够生产出在每一纵向和横向的耐火性小于每分钟2.54cm(1英寸)的织物，而且在某些情况下，在一个或两个方向可能自熄。
该织物还理想地具有好的稳定性，并且防脱层和剥离。相信这种高结合强度，能够使该织物获得优于传统型防渗透织物的耐洗性。“耐洗性”意指该织物能够在家用洗涤清洁剂和温度环境下，在常规洗衣机中经得起洗涤，并且更优选在工业条件下，使该织物经受更苛刻的温度和/或清洁剂，该工业条件能够被本领域普通技术人员所理解。此外，该织物能够理想地与例如聚氨酯泡沫的常规座椅织物衬底材料形成较强的结合。本领域的普通技术人员能够容易理解，此泡沫材料通常被用在座椅型材料的背面，以提供额外的缓冲并且帮助保护座椅的使用者免受例如弹簧的座椅构成部件的伤害。在与各种通常用作座椅材料衬底的聚氨酯泡沫结合时，根据ASTM D751(2001)测试，该织物理想地具有至少约3792.25Pa(0.55lbs/in2)的结合强度，更优选至少约5171.25Pa(0.75lbs/in2)。这表明该织物结构牢固地结合在一起，并且该泡沫牢固地结合到织物上。甚至更优选地，该泡沫织物具有约6895Pa(1lbs/in2)或更大的结合强度，并且进一步优选约7584.5Pa(1.1lbs/in2)或更大。本领域的普通技术人员能够容易理解，运输工具的制造通常需要总结合强度至少是3792.25Pa(0.55lbs/in2)；因此，本发明的织物可获得的高结合强度使其能够用于制造运输工具的座椅。
本发明的织物还理想地具有好的柔韧特性，从而赋予其优良的美观性，并与以前的防渗透型织物形成对比。特别地，根据ASTM D1399(1966)，Test Method for Stiffness of Fabrics，Option A测试，该织物理想地具有约120mm或更小的弯折长度硬度(bending length stiffness)，并且甚至更优选在每一纵向和横向约为100mm或更小，不论该织物是向上还是向下。甚至更优选地，当向上测试时，该织物具有低于约80mm的弯折长度硬度，并且进一步优选低于约60mm。本领域的普通技术人员能够容易理解，好的柔韧性不仅使该织物易于用在成型制品的生产，而且增强了例如座椅等物品的舒适性。此外，该织物能够很好的悬垂，从而使泡沫衬底或其它所需的附加材料易于应用。另外，通过引入例如抗菌剂、抗静电剂等附加的化合物，可以使该织物具有附加的性能。这可以被应用于任何其它层或作为一个单独的操作而进行。
如上所指出的，本发明的织物独特地结合了包括可清洁性、防流体渗透能力、耐燃性和柔韧性的特性。为了这个目的，该织物含有一个具有防污特性的织物基层。优选地，该织物基层通过例如氟化物整理剂的低表面能防沾化合物获得这种防污性能。
该织物基层能够以任何已知的方法制成，包括通过机织、针织、编织、无纺织物制造方法、纤维热轧法、或其组合。为了举例，本文进一步讨论的织物是机织织物；然而，应指明其它类型的织物也可用于本发明的范围。在使用机织织物时，应指明该织物可以是平织的，或者可以通过包括例如提花或多臂织造方法的方式来织造。在本发明的许多实施方式中，希望使用一种相对“紧密”的织物结构，这意味着该织物在构成织物结构的相邻纤维和/或纱线之间没有大的稀松区域。本领域的普通技术人员能够容易理解，这样的结构能够通过选择特殊的织物构造方法和编排，和/或例如热固着或热定形的后续加工方法而获得。对于特定的最终用途应用，该织物基层可以是任何所需要的重量。当织物用作运输工具的最终用途应用时，发现结合约169.54至约542.51g/m2(约5至约16oz/sq yd)重量的织物基层是理想的，并且更优选约271.26g/m2(8oz/sq yd)。
通过为特定的织物和预期的最终用途选择优化的织物特性，该织物可以由任何类型的纤维和/或纱线形成。例如，发现原液染色的聚酯纱线在本发明的织物中表现很好。然而，应当指出其它类型的材料包括但不限于例如聚酯、尼龙、聚丙烯和丙烯酸的合成材料，和例如棉、羊毛和类似物的天然材料，以及其混纺物。此外，该织物基层可以在需要时含有或基本上由木浆纤维组成。同时，可以根据织物特定的最终用途选择纱线的尺寸来优化该织物。例如，大纤度、细纤度、离裂型纤维(splittable fibers)、微细纤维、初生或长丝纤维、变形和扁平纤维、和其组合都可以用于本发明的范围。此外，该织物可以是扁平型织物(如平织织物)或者长毛绒或起绒织物、或者仿麂皮织物。在本发明的某些实施方式中，发现具有多毛表面的织物基层在最终结构中趋于具有特别理想的结合强度；这样的多毛表面是本领域的技术人员所共知的，并且通过下列方法就能够获得，例如在织物结构中引入发毛的纱线、机械或化学磨纱而形成该织物结构、或类似方法。例如，一类已经发现在本发明中表现很好的纱线是Albi型变形纱线，这是一种由大量原纤维构成的具有多毛表面的变形纱线。
该织物基层优选是着色的，即当用Hunter Color Eye(这种设备被本领域的普通技术人员所熟知)分析时，该织物的颜色具有约93或更小的L值。在本发明的一个优选实施方式中，该织物基层将被着色，这是由于该织物基层包含了例如原液染色聚酯的原液染色纤维和/或纱线，因为已经发现此纤维提供了理想的耐光性和可回收性，或由于该织物基层包含了原液染色尼龙，它与氯漂白剂接触时具有好的耐褪色性。然而，其它获得有色织物基层的方法也被考虑在本发明的范围内，包括但不限于使用例如卷装染色、纱线染色、或类似方法的其它方法染色的纱线，或者通过任何不连续的、连续的、或半连续的染色工序对织物基层染色，该染色工序包括但不限于匹染(piece dyeing)、热熔染色(thermosol dyeing)、喷射染色、range dyeing、或类似方法。此外，该织物基层可以被印花或通过其它任何已知的方法着色。
如所指出的，该织物基层理想地具有防污特性。为了这一目的，该织物基层和/或构成该织物基层的组分可以经过防污化合物处理，例如低表面能防污化合物。优选地，该防污化合物含有或者基本上由氟化物(并且优选高度耐用、高度疏水和疏油的氟化物)组成，并且将该化合物至少应用于织物基层的第一表面。例如，低表面能防污化合物可以通过以下方法应用于织物：通过设计的工序使该化合物只保持在其应用的表面(例如通过某种发泡、滚动应用(roll application)、喷雾方法、或类似方法)，或者该化合物可以被应用以便影响织物的两个表面，这是通过对整个织物的应用(例如通过浸轧应用方法)或通过对两个织物基层表面的单面应用而进行的。另外，该织物可以由已经用低表面能防污化合物处理的组分制造，例如通过在织物形成前将该化合物应用于纱线。如上面所指出，低表面能防污化合物的应用，通常趋于降低织物基层粘合附加材料的能力，并且增加了可燃性。然而，这种化合物为该材料提供了好的防污性和可清洁特性。
在本发明的一个实施方式中，低表面能防污化合物处理的织物基层随后用稳定层处理，该稳定层优选乳胶层或者溶剂性聚合物层、塑料溶胶、和/或其它聚合物涂层。优选地，该稳定层含有或者基本上由Tg低于约10℃的丙烯酸乳胶组成。在本发明的一个特别优选的实施方式中，固有的或者通过包含耐燃化合物，此丙烯酸层是耐燃的。合适的耐燃化合物包括但不限于cyclic phoshonate、卤代烷烃、溴化环、或类似物、或其组合。已经发现这一稳定层改善了织物基层的尺寸稳定性，减少起球，并且防止组成的纱线和纤维从织物基层中被轻易地拉出，比如通过抽丝。此层优选以约8.48至约254.30g/m2(约0.25至约7.5oz/sq yd)的等级应用，并且更优选约67.81g/m2(2oz/sq yd)的等级。当所用的织物基层用低表面能防污化合物仅在单面处理时，该丙烯酸理想地应用于该织物基层的另一表面。该丙烯酸可以通过任何已知的方法应用，包括但不限于涂覆方法、喷雾方法、挤压方法、辊或者吻合涂布应用方法、发泡、或类似方法。该稳定层优选用作一个连续层；然而，如需要，它可以以一种不连续的方式提供，例如一种随意或预定的方式。刮刀涂布是一个优选的应用方法，因为已经发现它为织物基层提供很好的连续覆盖。该丙烯酸需要干燥，优选通过在拉幅机上于大约148.9至大约204.4℃(大约300°至大约400°F)进行干燥，并且更优选大约176.7℃(350°F)。
在本发明的这个实施方式中，随后将粘合剂材料理想地应用于稳定材料处理的织物基层。该粘合剂理想地是含有弹性组分的聚合材料。可以使用的粘合剂材料的例子是金属茂聚乙烯(metallocenepolyethylene)、丙烯酸酯聚合物(如甲基丙烯酸酯聚合物)、聚氨酯、聚丙烯组合物、PET聚酯组合物、聚对苯二甲酸丁二醇酯(PBT)聚酯组合物、人造橡胶聚乙烯(elastomeric polyethylene)、聚氨酯、人造橡胶聚乙烯、和其结合或共混物。在本发明这个实施方式的一个特别优选的形式中，该粘合剂材料是金属茂聚乙烯粘合剂。尽管预期该粘合剂的厚度通常是约0.00254至约0.127mm(约0.1至约5mils)，且更优选从约0.0127至约0.0762mm(约0.5至约3mils)，但该粘合剂应用的厚度和使用的应用方法，可由制造者根据其希望用的设备类型、使用的粘合剂类型、和该织物预期的最终用途来选择。对于本发明的这个特殊的实施方式，已经发现通过挤压涂覆工序，以约0.0254-0.0508mm(1-2mils)的厚度应用金属茂，制成一个最终用途例如是运输工具座椅的好的产品。
随后，需要将防渗透材料应用于该粘合剂材料层。可以使用的防渗透材料的例子包括但不限于聚氨酯、聚酯、聚烯烃、烯烃共聚物、橡胶(天然和合成的)、硅树脂、聚偏二氯乙烯、聚偏二氟乙烯、聚氯乙烯、聚氟乙烯、它们的塑化形式，和其组合或共混物。优选地，该防渗透材料的拉伸模量低于织物，而且是柔韧的，以便保持结合强度且防脱层。在本发明的这个特殊的实施方式中，已经发现通过金属茂聚乙烯层将0.0254-0.0508mm(1-2mil)的聚酯聚氨酯或聚醚聚氨酯薄膜层压到织物结构，制成一种理想的最终产品。尽管在这个实施方式中说明了薄膜的层压方法，应当指出其它提供防渗透材料层的方法也可以规定在本发明的范围内。例如，防渗透材料可以通过挤压、涂覆方法、转移方法、涂覆、喷雾、发泡或类似方法应用。然而，已经发现层压聚氨酯薄膜，在织物结构上提供了好的聚氨酯连续层。防渗透材料使用的厚度可以根据所用材料的特定类型、使用的应用方法、和该织物预期的最终用途来选择。在本发明的这个特殊例子中，已经发现厚度约0.00635至约0.127mm(约0.25至约5mils)的聚氨酯薄膜，更优选厚度约0.0254至约0.0762mm(约1至约3mils)的聚氨酯薄膜，可以很好地生产例如制造运输工具座椅的织物。在本发明的一些实施方式中，该防渗透层还含有耐燃化合物，在本文将进一步讨论。
在设计用于特殊最终用途的本发明的某些实施方式中，可能期望将泡沫层应用于织物。例如，在一些座椅型应用中，希望提供一种泡沫层，从而为织物提供附加的缓冲能力，并保护该织物免受例如弹簧和类似物的座椅支撑结构的组成部件影响。在本发明的这个实施方式中，希望选择能牢固地结合到该泡沫材料的防渗透材料。上述具有聚氨酯薄膜防渗透层的本发明的实施方式，已经发现与各种通常用于制成汽车座椅型织物的传统聚氨酯泡沫结合得很好。泡沫的应用可以通过例如粘合剂粘合或类似的结合方法，或者可以通过例如焰熔层压的层压方法来实现。然而，该泡沫的其它应用和固定方法也可以在本发明的范围内使用。
在这个实施方式中说明的织物具有好的悬垂特性(由其高柔韧/可挠程度而证明)、好的防流体渗透性、好的防污性、阻燃性和结合强度。事实上，正如将在下面的实施例中所证明的，意外地发现根据本发明制成的织物能够满足或超过汽车织物所要求的严格标准，并且具有迄今所能达到的较先进的可清洁能力和美观水平。
在本发明的另一实施方式中，提供了具有先前说明的各种低表面能防污处理的织物基层。在本发明的这个实施方式中，应用丙烯酸整理剂的步骤被省去，并且将粘合剂层应用于织物基层本身。在本发明的这个实施方式中，防渗透材料层优选含有添加剂从而适合增加其耐燃性，以便改善整个织物的耐燃性。例如，可以使用与前述相同的聚氨酯基本成分，但该聚氨酯被改性以结合有效量的FR添加剂，从而使织物能够达到该织物预期的最终用途所需的耐燃性特定级别。合适的阻燃剂可以在其中包括cyclic phoshonate、卤代烷烃、溴化环、或类似物。在本发明的另一实施方式中，丙烯酸和粘合剂层都被省去，而弹性材料层被改性并引入有效量的FR阻燃剂，以使其达到一个耐燃的所需级别。然而，在这个实施方式中，必须小心以确保维持优良的柔韧性和粘合程度。
如先前所指出，该织物可以包括附加的特性，例如防紫外辐射、抗菌特性、抗静电特性等。已经发现效果好的防紫外辐射剂是苯并三唑、改性三嗪或类似物，并且发现它们可以与防污化合物同时应用，或者作为一个单独的操作应用。
当希望有抗菌特征时，抗菌剂可以至少置于织物基层的第一面或者织物的两个表面。该抗菌剂可以通过喷雾、发泡应用、吻合涂布，或类似方法置于织物基层的第一面，或者通过浸没涂覆、浸轧、或类似方法置于该织物基层的两面。该抗菌剂还可以通过在染色循环中，将抗菌剂排到织物上来置于织物基层。此外，可以将该抗菌剂引入形成织物基层的纤维中。作为另一个选择，可以将该抗菌材料提供到织物的其它材料层中，或者作为一个单独的独立层。合适的抗菌剂包括但不限于银、silicon quat、三氯生、和有机锡。该抗菌剂可以以有效的最小抑制浓度应用，例如1.00％水平的DM-50，DM-50是可由ThompsonResearch of Toronto，Canada获得的商品化的抗菌剂。本领域的普通技术人员应该能够理解，在织物中引入的抗菌剂可能提供某些理想的性能，例如抗霉性、气味控制等。
抗静电剂可以至少置于织物基层的第一面。该抗静电剂可以通过喷雾、发泡应用、吻合涂布，或类似方法置于织物基层的第一面，或者通过浸没涂覆、浸轧、或类似方法置于该织物基层的两面。该抗静电剂可以与低表面能防污化合物一起置于织物基层，或者在一个独立的步骤，连同或不连同其它试剂置于织物基层上。合适的抗静电剂可以包括高度乙氧基化的酯、季铵化合物、或类似物。
本文前面讨论的织物的防流体渗透性能主要集中于其防液体渗透能力，应该指出该织物也可以用于阻隔其它流体，例如空气和/或其它气体。这由下面说明的Mullen Burst数据得到证明，该数据是织物阻止空气通过程度的指标。不希望限制于理论，相信这种出众的透气性可能部分归因于在本发明的一些实施方式中使用的独特组合的涂层和薄膜。换句话说，本发明者相信提供单独的涂层可能留下较差的涂覆区域，在该涂覆区域中，原纤维或者其它三维突起存在于织物基层上。通过提供如本发明的一些实施方式中说明的涂层和薄膜的组合，相信薄膜用于覆盖这些较差的涂层，由此使防渗透性能达到一个不寻常的水平。
这些和其它添加剂可以结合于一层或更多其它层，或者作为一个单独操作应用，或者在原织物基层上提供，或者作为其原始组分的一部分(例如通过使用本身抗菌或抗静电的纤维)。
虽然已说明该产品的制造包括提供几个不同层，但是应该指出在可能的情况下该应用方法可以变化而优化制造效率。例如，可以使用多组分薄膜，在一个单独的操作中提供多层(例如已在防渗透膜上提供了粘合剂的双组分薄膜)。
实施例
大量织物样品的制造如下：检测样品的各种特性，包括防流体渗透性能(静水压试验，Hydrostatic Pressure Test，和喷淋试验，Spray Test)、防污性(抗油性试验，Oil Repellancy Test)、耐燃性(燃烧速率、燃烧时间和烧焦长度试验，Burn Rate，Burn Time and Char Length Tests)、结合强度(结合强度试验，Bond Strength Test)、防紫外性(UV Test)、热震性能(热震试验，Thermal Shock Test)、和摩擦脱色性(Colorfastness toCrocking Test)。
防流体渗透性能：如本文所使用的，防流体渗透性能是通过American Association of Textile Chemist and Colorists(AATCC)WaterResistance：Hydrostatic Pressure Test Method 127-1998，和WaterRepellency：Spray Test Method 22-1996测定的，并在此完整引入本文作为参考。本发明发表的防渗透织物，通过AATCC Water Resistance：Hydrostatic Pressure Test TM 127-1998测定，具有约50毫巴或更大的耐静压，并且更优选大于约100。甚至更优选地，该织物具有约150毫巴或更大的耐静压，并进一步优选约200毫巴或更大。本发明发表的防渗透织物，通过AATCC Water Repellency：Spray Test TM 22-1996测定，具有约70(IS04)或更大的抗水率(water repellency rating)。
防污性：如本文所使用的，防污性能是通过AATCC Oil Repellency：Hydrocarbon Resistance Test Method 118-1997测定的，并在此完整引入本文作为参考。本发明发表的防渗透织物的防污性，通过AATCC OilRepellency：Hydrocarbon Resistance Test TM 118-1997测定，是约Grade3或更大，并且更优选约Grade 4或更大。在本发明的某些实施方式中，耐油性是约5或更大，最大级别高达8。
防紫外性：如本文所使用的，防紫外性能是通过SAE RecommendedPractice SAE J1885 MAR92，Accelerated Exposure of Automotive InteriorTrim Components Using A Controlled Irradiance Water Cooled Xenon-ArcApparatus测定的，并在此完整引入本文作为参考。本发明发表的防渗透织物的防紫外性，通过SAE J1885 MAR92测定，其ΔE在225kj显示为约4.0或更小。
热震性能：如本文所使用的，热震性能是通过将织物样品加热到约100℃，将该样品应用于约36.7℃(98°F)主要为水的模拟体(simulated body)，然后测量一秒钟后该织物样品与模拟体之间接触面的温度而测定的。该样品是大约2096.8cm2(325平方英寸)的一片织物，并装在一个3mm厚的聚氨酯泡沫衬底上。该模拟体是含有琼脂凝胶稳定剂的大约25磅水，装在一个塑料袋中。界面温度通过在塑料袋表面放置一个热电偶来测量。本发明发表的防渗透织物在与模拟体接触一秒后，经历约35℃或更少的温度。
耐燃性：如本文所使用的，耐燃性能通过FMVSS-302 Test Method测定，并在此完整引入本文作为参考。本发明的防渗透织物，在本发明的一些实施方式中，理想地具有约10.16cm(4英寸)或更小的燃烧速率，证明其具有充分的耐燃性，从而使它们达到目前政府对汽车内饰织物的耐燃要求。当“SE”出现在实验结果中时，表明该织物是自熄的。
摩擦脱色性：如本文所使用的，摩擦脱色性能是通过AATCCColorfastness to Crocking：AATCC Crockmeter Method TM 8-1996测定的，并在此完整引入本文作为参考。本发明发表的防渗透织物的耐摩擦脱色性，通过AATCC Colorfastness to Crocking：AATCC CrockmeterMethod TM 8-1996测定，约是3或更大。
抗静电性能：如本文所使用的，抗静电性能是通过AATCCElectrical Resistivity of Fabrics Test Method TM 76-1978测定的，并在此完整引入本文作为参考。本发明发表的防渗透织物的抗静电性能，通过AATCC Electrical Resistivity of Fabrics Test Method TM 76-1978测定，是每平方约1012欧姆或更小，并且优选在每平方约1010与约1012欧姆之间。
弯折长度硬度：如本文所使用的，织物的弯折长度硬度，是在不存在张力下，将两个相同且相对的力沿着平行线作用于被弯曲的织物条的某一端，从而测量硬度，该弯折长度硬度是通过ASTM D 1388(1996)，Standard Test Method for Stiffness of Fabrics，Option A测定的。
抗挠刚度：如本文所使用的，织物的抗挠刚度是织物重量与织物硬度之间的相互作用，该相互作用通过织物在其自身重量下弯曲所反映，而该抗挠刚度是通过ASTM D 1388(1996)，Standard Test Method forStiffness of Fabric，Option B测定的。
圆弯曲硬度(Circular Bend Stiffness)：如本文所使用的，织物的圆弯曲硬度是织物抵抗多方向弯曲的测量，通过ASTM D 4032(1994)，Standard Test Method for Stiffness of Fabric by the Circular BendProcedure测定。
结合强度-结合强度是根据ASTM D 751(2001)检测的。通常，对于汽车座椅应用需要0.55或更大的结合强度。
Mullen Burst-样品F根据ASTM D3786-87检测，而用该织物样品代替传统使用的薄膜。这种试验方法在此引入作为参考。所得的较高数值表明该织物能够很好地作为例如空气的气体阻隔层，由此将很好地用于充气式和其它相似类型的阻隔层最终用途中。
每个样品A-G都使用一种具有大约每英寸60经纱和每英寸45纬纱的大约271.26g/m2(8oz/sq yd)的100％聚酯织物。该织物在每一经纱和纬纱中用2股150长丝变形聚酯纱线织造。该织物用下述多种不同的方式处理。
样品A-将有效量的氟化物整理剂浸轧到织物上，随后该织物通过挤压涂覆将0.0381mm(1.5mil)的EMA(乙烯丙稀酸甲酯，ethylenemethyl acrylate)涂层涂于背面。该织物根据上述试验方法检测粘合和燃烧。这些测试结果列于下表A-C。
样品B-将有效量的氟化物整理剂，以与样品A同样的方法浸轧到织物上，随后将0.0381mm(1.5mil)的聚丙烯/聚丁烯共混物涂层涂于该织物背面。该织物根据上述试验方法检测粘合和燃烧。这些测试结果列于下表A-C。
样品C-将有效量的氟化物整理剂，以与样品A同样的方法浸轧到织物上，随后用0.0381mm(1.5mil)的乙烯丙烯酸甲酯涂层，代替样品B中的聚丙烯/聚丁烯涂层，涂于该织物背面。该样品根据上述试验方法检测粘合和燃烧。这些测试结果列于下表A-C。
样品D-将有效量的氟化物整理剂，以与样品A同样的方法浸轧到织物上，随后将耐FR的丙烯酸涂层以约67.81g/m2(2oz/sq yd)的等级涂于该织物背面。将0.0508mm(2mil)的聚氨酯薄膜层压到该织物的丙烯酸涂层表面。检测该织物的结合强度、防流体渗透性能(喷淋试验和静水压试验)、污物释放和燃烧速率。这些测试结果列于下表A-C。
样品E-将有效量的氟化物整理剂，以与样品A同样的方法浸轧到织物上，随后将0.0508mm(2mil)的聚氨酯薄膜以样品D的方式层压到该织物表面(然而这次没有丙烯酸中间层)。检测该织物的防流体渗透性能(喷淋试验和静水压试验)、污物释放和燃烧速率，但是该织物是卷起的而不能检测结合强度。这些测试结果列于下表A-C。
样品F-将有效量的氟化物整理剂，以与样品A同样的方法浸轧到织物上，随后将丙烯酸以67.81g/m2(2oz/sq yd)的等级涂覆到该织物。将织物干燥，然后以0.0508mm(2mils)挤压涂覆金属茂粘合剂。通过该金属茂粘合剂，将0.0508mm(2mil)的聚醚氨酯薄膜(PT-5000，来自Deerfield Urethane of South Deerfield，Massachusetts)层压到该织物。检测该织物的防污性、防流体渗透性能、和耐燃性，并且将结果列于下表A-C。还检测了该织物的Mullen Burst，并将结果列入下表D。(如表D所显示，测试了两个织物样品的八个不同例子，并显示了平均结果)。
样品G-样品G以与样品F相同的方法制备，仅有的不同是应用了0.0254mm(1mil)的聚酯聚氨酯薄膜(PS-8010，也来自DeerfieldUrethane)而不是0.0508mm(2mil)的聚醚氨酯薄膜。在样品F中检测的特性，同样在该织物中检测，并且将结果列于下表A-D。
表A-结合强度
样品                 结合强度(Pa)(括号中为lbs/in2)
样品A                1723.75(0.25)
样品B                2137.45(0.31)
样品C                1930.6(0.28)
样品D                7584.5(1.1)
样品E                5171.25(0.75)
样品F                7584.5(1.1)
样品G                8274(1.2)
表B
样品    油级    沾水等级     静水压(Pa)(括号中为mb)
样品A   4-5     50-70        5500-6000(55-60)
样品B   5-6     80-100       5000-5500(50-55)
样品C   5-6     80-100       5000-5500(50-55)
样品D   5       90           5000(50)
样品E   5       100          5500(55)
样品F   4       80           20000(200)
样品G   5       80           ＞20000(＞200)
表C
            经纱烧   纬纱烧   经纱燃  纬纱燃   经纱燃    纬纱燃
样品        焦长度   焦长度   烧时间  烧时间   烧速率    烧速率
            (in)     (in)     (sec)   (sec)    (in/min)  (in/min)
样品A       10       ＞10     96      81       6.25      ＞7.4
样品B       8        ＞10     98      90       4.9       ＞6.7
样品C       8        ＞10     102     88       4.7       ＞6.8
样品D       0        0        0       0        SE        SE
样品E       0        0        0       0        SE        SE
样品F       1.6      3.4      25      105      SE        1.94
样品G       0        2.6      0       93       SE        1.68
表D-Mullen Burst
        #1    #2    #3    #4    #5    #6    #7    #8    平均
样品F   58    48    57    57    49    67    57    50    55
样品G   50    40    40    46    48    46    36    65    46
如以上实施例所示，根据本发明制得的织物，独特地结合了约0.55或更大的结合强度与约50或更大(而事实上，基本上是更大)的抗流体静力。换句话说，该织物独特地结合了耐用性和防流体渗透性能，同时保持了优于以前所达到水平的悬垂性。此外，这是在获得高级别的耐燃性时实现的，因此该织物能够在运输工具最终用途应用中用作座椅织物。
实施例H-一种3×3斜纹织物，可以由3/150聚酯经纱和3/150纬纱，以每英寸约35纬纱和每英寸约50经纱制成。将有效量的氟化物整理剂浸轧到该织物上，随后通过刮刀涂布方法，将约65g/m2丙烯酸乳胶涂于该织物背面。通过使用约10g/m2低熔融温度的，由薄膜外应用的加热辊活化的共聚酯粘合剂，将约20g/m2的聚醚聚氨酯薄膜也结合到该织物的丙烯酸乳胶涂层面。成品织物的重量应该约为380g/m2。随后，根据上述试验方法可以检测该成品织物的弯折长度硬度、抗挠刚度和圆弯曲硬度，并将结果列于表E-G。
表E-弯折长度硬度
             向上                向下
实施例
         经向(mm)    纬向(mm)    经向(mm)     纬向(mm)
实施例H    120        92            51         53
表F-抗挠刚度
实施例        经向                纬向
实施例H     5.84cm(2.3英寸)     7.11cm(2.8英寸)
表G-圆弯曲硬度
              向上                  向下
实施例
         最大负荷(克力)  模量(psi)  最大负荷(克力)  模量(psi)
实施例H     4897           5.5          6515          10.5
如实施例H所示，本发明制成的样品可以具有约120mm或更小的弯折长度硬度，和其它有利的硬度和柔韧特性。
尽管已经说明本发明的织物作为运输工具材料特别有用，但是应当指出该织物也可用于其它最终用途中，包括但不限于船罩、户外家具和遮阳蓬、例如空气垫的可充气物品、救生器材和救生艇，和枕头、室内家具(家用和商用)、窗帘、浴帘、覆墙产品、屏风、医药和医院应用、雨伞、遮雨布、恶劣天气条件下所有类型的保护物、外科手术隔离衣、服装、隔离衣、帐篷、背包、和类似物。对于这些其它的最终用途，为了使织物特别适合于该预期的最终用途，可能希望改变例如耐燃性、防紫外辐射能力、透气性水平、结合强度等性能。例如，当织物被用作例如户外家具或遮阳蓬的户外织物时，可能希望该织物对紫外辐射的防护，根据AATCC Test Method 186-2000在喷雾增湿环境(spray humidity environment)和荧光照射下检测，达到约200至300小时或更大。同样，也可以设计例如抗药性和柔韧性级别，而根据特殊的最终用途获得优化的最终产品。
在本说明书中已经说明了本发明的优选实施方式，尽管使用了特定术语，但是它们仅用于一般性和描述性的意义，而不是为了限制，本发明的范围在权利要求书中定义。

Claims (15)

1.一种防渗透织物，所述防渗透织物包括：
具有第一面和第二面的织物基层；
至少置于所述织物基层第一面的氟化物；
置于所述织物基层第二面的丙烯酸乳胶；
置于所述丙烯酸乳胶上的共聚物粘合剂；
置于所述共聚物粘合剂上的聚酯聚氨酯防渗透膜。
2.一种防渗透织物，所述防渗透织物包括：
具有第一面和第二面的织物基层；
至少置于所述织物基层第一面的低表面能防污化合物；
置于所述织物基层第二面的聚合物稳定层；
置于所述聚合物稳定层上的粘合剂，其中所述粘合剂包括含有弹性组分的聚合材料；和
置于所述粘合剂上的防渗透膜。
3.根据权利要求2所述的防渗透织物，其中所述低表面能防污化合物包含氟化物。
4.根据权利要求2所述的防渗透织物，其中所述聚合物稳定层包含丙烯酸乳胶。
5.根据权利要求2所述的防渗透织物，其中所述聚合物稳定层以不连续的方式置于所述织物基层上。
6.根据权利要求5所述的防渗透织物，其中所述聚合物稳定层以预定的方式置于所述织物基层上。
7.根据权利要求2所述的防渗透织物，其中所述防渗透膜包含聚氨酯薄膜。
8.根据权利要求7所述的防渗透织物，其中所述防渗透膜包含聚酯聚氨酯薄膜。
9.根据权利要求7所述的防渗透织物，其中所述防渗透膜包含聚醚聚氨酯薄膜。
10.根据权利要求7所述的防渗透织物，其中所述粘合剂包含金属茂聚乙烯。
11.根据权利要求2所述的防渗透织物，进一步包括结合到所述防渗透膜上的泡沫材料。
12.根据权利要求11所述的防渗透织物，其中所述泡沫材料包含聚氨酯泡沫。
13.根据权利要求12所述的防渗透织物，其中所述泡沫材料焰熔层压到所述防渗透层上。
14.根据权利要求11所述的防渗透织物，其中所述泡沫材料通过又一粘合剂结合到所述防渗透层上。
15.根据权利要求11所述的防渗透织物，其中所述泡沫材料层压到所述防渗透层上。
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JP2010208347A (ja) 2010-09-24
CA2507180A1 (en) 2004-06-17
EP1565310A1 (en) 2005-08-24
KR20050084028A (ko) 2005-08-26
US20040102113A1 (en) 2004-05-27
MXPA05005559A (es) 2005-07-26
EP1565310A4 (en) 2010-10-20
BR0316612A (pt) 2005-10-11
JP2006507959A (ja) 2006-03-09
US6833335B2 (en) 2004-12-21
WO2004050354A1 (en) 2004-06-17
HK1085975A1 (en) 2006-09-08
RU2005120010A (ru) 2006-01-20
EP1565310B1 (en) 2014-09-03
CN1717324A (zh) 2006-01-04

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