EP0379100A1 - Flame-resistant carrier web for bitumen webs, and process for producing the same - Google Patents

Flame-resistant carrier web for bitumen webs, and process for producing the same Download PDF

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Publication number
EP0379100A1
EP0379100A1 EP90100667A EP90100667A EP0379100A1 EP 0379100 A1 EP0379100 A1 EP 0379100A1 EP 90100667 A EP90100667 A EP 90100667A EP 90100667 A EP90100667 A EP 90100667A EP 0379100 A1 EP0379100 A1 EP 0379100A1
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EP
European Patent Office
Prior art keywords
melamine
formaldehyde
carrier web
web according
sulfamate
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.)
Granted
Application number
EP90100667A
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German (de)
French (fr)
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EP0379100B1 (en
Inventor
Peter Dr. Heidel
Wilhelm Dr. Adam
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Hoechst AG
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Hoechst AG
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Publication date
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Publication of EP0379100A1 publication Critical patent/EP0379100A1/en
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Publication of EP0379100B1 publication Critical patent/EP0379100B1/en
Anticipated expiration legal-status Critical
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645—Impregnation followed by a solidification process
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/66—Additional nonwoven fabric is a spun-bonded fabric
    • Y10T442/662—Needled
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/682—Needled nonwoven fabric
    • Y10T442/684—Containing at least two chemically different strand or fiber materials
    • Y10T442/685—Containing inorganic and polymeric strand or fiber materials

Definitions

  • the present invention relates to a multi-layer, flame-retardant carrier sheet and its production and to a bituminized roofing and sealing sheet containing this carrier sheet.
  • carrier sheets for roofing and waterproofing membranes which concern their further processing into roofing and waterproofing sheets and the behavior of the latter during and after laying on the documents.
  • High strength of the carrier web in a wide temperature range is intended to ensure high processing and dimensional stability when bituminizing and the fire behavior, assessed according to DIN 4102, Part 7, is to be met.
  • the carrier sheet should also ensure high dimensional stability of the finished roofing and waterproofing membrane when laid on the roof or other substrates, as well as high flexibility and a certain degree of elasticity to compensate for irregularities and weather-related dimensional changes of the covered substrate.
  • Carrier sheets for bituminized roofing and waterproofing sheets are described, for example, in European laid-open publications 0 176 847 and 242 524. They preferably consist of two nonwovens, for example a glass fiber mat and a polyester fiber mat, which are connected to one another by needling. The needled laminate is then finally consolidated with a binder, acrylate-butadiene or acrylate-butadiene-styrene copolymers being generally used.
  • German Offenlegungsschrift 26 19 087 e.g. described for polyester spunbonded binders, consisting of an acrylate-butadiene-styrene copolymer with an addition of 5 to 30 wt .-% of a melamine-formaldehyde precondensate.
  • a method for producing flame-retardant nonwovens is known from German patent specification 11 49 688.
  • a flame retardant is applied to the nonwoven at the same time as the binder.
  • tetrahydrophosphonium chloride is used as the flame retardant, which is applied together with a binder system composed of natural rubber latex and a melamine-formaldehyde precondensate.
  • the fleece is also solidified with a melamine-formaldehyde precondensate.
  • the nonwovens equipped in this way are poorly suited for the production of flame-retardant bitmunised roofing and waterproofing membranes in accordance with DIN 4107, Part 7, since for this purpose they must contain a very large amount of flame retardants, for example antimony trioxide or phosphorus compounds. This high proportion of flame retardants leads to a very strong reduction in the flexibility of the nonwovens, so that in this respect they no longer meet the requirements for the production of roofing and waterproofing membranes.
  • flame retardants for example antimony trioxide or phosphorus compounds.
  • the present invention now relates to a carrier sheet for the production of roofing and sealing sheets which does not have the disadvantages of the known materials, in which high mechanical stability is combined with very good fire behavior even at elevated temperatures.
  • the carrier web according to the invention consists of a glass fiber mat and a hat made of synthetic fibers, which are needled together and which are finally consolidated with a polymer-free, low-formaldehyde melamine-formaldehyde precondensate.
  • the glass fiber mat contained in the carrier web according to the invention can in the usual way with the usual binders, i.e. usually polymer binders or melamine resins are pre-consolidated.
  • the synthetic fiber fleece contained in the carrier web according to the invention can be made from all types of synthetic fibers which have sufficient strength.
  • synthetic fibers which have sufficient strength.
  • aliphatic and aromatic polyamides, polyacrylonitrile and in particular polyester fibers are suitable.
  • fiber types that have high strength, high modulus and low heat shrinkage, so that the dimension of the carrier web remains constant during further processing to form roofing and waterproofing membranes.
  • a particularly preferred synthetic fiber material consists of polyethylene terephthalate, especially the high-strength and low-shrink types.
  • the synthetic fiberylies consist of flame-resistant polyesters.
  • Examples of commercially available synthetic fibers from which the Synthetic fiber fleece can be constructed are (R) Trevira, in particular the high-strength types and the flame-retardant type (R) Trevira CS.
  • the synthetic fiber fleece can be constructed from staple fibers, advantageously with cutting lengths between 1 and 100 mm, or from continuous fibers. Tangled nonwovens made from continuous fibers are particularly preferred, in particular types which have undergone a certain degree of pre-consolidation through a calendering process, such as e.g. the so-called spunbonds.
  • the low-formaldehyde melamine-formaldehyde precondensate with which the carrier web according to the invention is finally consolidated has a molar ratio of melamine to formaldehyde of 1: 1.0 to 1: 3.5, preferably 1: 1.2 to 1: 3.
  • the partially etherified precondensates are partially etherified with lower alkanols, ie those with 1 to 4 carbon atoms, but especially with methanol.
  • the degree of etherification of the partially etherified precondensates is characterized in that they have 0.2 to 0.85, preferably 0.6 to 0.8, mol of ether groups per mole of formaldehyde.
  • Particularly preferred low-formaldehyde partially etherified melamine-formaldehyde precondensates have a molar ratio of melamine to formaldehyde of 1: 2 to 1: 3 and have 0.6 to 0.8 mol of methyl ether groups per mol of formaldehyde.
  • Sulfamate-modified low-formaldehyde melamine-formaldehyde precondensates contain, based on solid resin, 1 to 20% by weight, preferably 5 to 15% by weight, of sulfamate, calculated as sodium sulfamate.
  • Particularly preferred sulfamate-modified melamine-formaldehyde precondensates have a molar ratio of melamine to formaldehyde of 1: 1.2 to 1: 2 and, based on solid resin, have 5 to 15% by weight sulfamate, calculated as sodium sulfamate.
  • the melamine-formaldehyde precondensate contained in the carrier web according to the invention additionally contains a small amount, i.e. 1 to 5% by weight, based on solid resin, contains further modifying agents, in particular modifying agents which increase plasticity, as long as this does not unduly reduce the necessary flame resistance.
  • Plasticizing additives of this type are e.g. Di- and triethylene glycol and their ethers or polyethylene glycols with molecular weights up to 2000.
  • carrier webs according to the invention which are solidified with a melamine-formaldehyde precondensate without additional plasticizing modifiers.
  • Carrier webs according to the invention which have a combination of several preferred features are also particularly preferred.
  • the carrier web according to the invention has the advantage over known carrier webs that it exhibits improved fire behavior with a high degree of flexibility which is very accommodating for further processing. In this respect, it is considerably superior to both the nonwoven materials known from DE-AS 1 149 688 and the nonwoven materials produced using a binder according to DE-OS 26 19 087.
  • the mechanical load-bearing capacity of the carrier web according to the invention under the influence of heat (temperature range, e.g. 180 ° C.), as occurs during further processing into roofing and waterproofing membranes, has also been significantly improved.
  • the same applies to the tear propagation resistance of the carrier web according to the invention which is increased by approximately 25% compared to carrier webs which are finally consolidated with polyacrylate binders.
  • one of the above specified is used Synthetic fiber nonwovens needled with an optionally pre-consolidated glass fiber fleece and then with an aqueous melamine-formaldehyde precondensate of the above-mentioned specification, to which approximately 0.5 to 3% of a known hardener, for example a hardener based on p-toluenesulfonic acid, has advantageously been added Spraying, splashing or, preferably, dipping impregnated to the required resin absorption of 5 to 40, preferably 15 to 30,% by weight, based on unimpregnated material, optionally squeezed out and then dried in a heating oven, generally at temperatures between 80 to 200, preferably 120 to 180 ° C, hardened in the course of 5 to 30 minutes.
  • the production of the carrier web according to the invention is also the subject of the present patent application.
  • the carrier web according to the invention can be used for very different purposes with particular advantage. It can e.g. can be used as a decoration support due to their flame retardancy. Their use as a carrier material for bituminized roofing and waterproofing membranes is particularly preferred.
  • the use according to the invention of the low-formaldehyde melamine-formaldehyde precondensates specified above also offers advantages in the production of the carrier web according to the invention: namely, glass nonwovens with a relatively low binder content can be used. Since the character of the binder plays a minor role when the binder content is low, e.g. cheaper glass fleeces with a lower binder content, which do not have to be flame-retardant, can be used.

Abstract

A carrier web of a sheet-like fiber material consisting of a glass fiber mat and a mat of synthetic fibers, which and are needled together and are end-consolidated with a polymer-free low-formaldehyde melamine-formaldehyde precondensate, and a process for its preparation are described. The carrier web is preferably end-consolidated with a melamine-formaldehyde precondensate which is partly etherified and/or sulfamate-modified.

Description

Die vorliegende Erfindung betrifft eine mehrschichtige, schwer brennbare Trägerbahn und ihre Herstellung sowie eine diese Trägerbahn enthaltende bituminierte Dach- und Dichtungsbahn.The present invention relates to a multi-layer, flame-retardant carrier sheet and its production and to a bituminized roofing and sealing sheet containing this carrier sheet.

An Trägerbahnen für Dach- und Dichtungsbahnen werden verschiedene wichtige Anforderungen gestellt, die ihre Weiterverarbeitung zu Dach- und Dichtungsbahnen und das Verhalten der letzteren beim und nach dem Verlegen auf den Unterlagen betreffen. Hohe Festigkeit der Trägerbahn in einem weiten Temperaturbereich soll eine hohe Verarbeitungs- und Dimensionsstabilität beim Bituminieren sicherstellen und das Brandverhalten, beurteilt nach DIN 4102, Teil 7, soll erfüllt werden. Gleichzeitig soll die Trägerbahn auch hohe Dimensionsstabilität der fertigen Dach- und Dichtungsbahn bei der Velegung auf dem Dach oder sonstigen Untergründen sowie hohe Flexibilität und eine gewisse Dehnbarkeit zum Ausgleich von Unregelmäßigkeit und witterungsbedingten Dimensionsänderungen des gedeckten Untergrunds gewährleisten.Various important requirements are placed on carrier sheets for roofing and waterproofing membranes, which concern their further processing into roofing and waterproofing sheets and the behavior of the latter during and after laying on the documents. High strength of the carrier web in a wide temperature range is intended to ensure high processing and dimensional stability when bituminizing and the fire behavior, assessed according to DIN 4102, Part 7, is to be met. At the same time, the carrier sheet should also ensure high dimensional stability of the finished roofing and waterproofing membrane when laid on the roof or other substrates, as well as high flexibility and a certain degree of elasticity to compensate for irregularities and weather-related dimensional changes of the covered substrate.

Trägerbahnen für bituminierte Dach- und Dichtungsbahnen sind z.B. in den Europäischen Offenlegungsschriften 0 176 847 und 242 524 beschrieben. Sie bestehen vorzugsweise aus zwei Vliesstoffen, z.B. einer Glasfasermatte und einer Polyesterfasermatte, die durch Nadlung miteinander verbunden sind. Der vernadelte Schichtstoff wird dann noch mit einem Bindemittel endverfestigt, wobei in der Regel Acrylat-­Butadien- oder Acrylat-Butadien-Styrol-Copolymerisate eingesetzt werden.Carrier sheets for bituminized roofing and waterproofing sheets are described, for example, in European laid-open publications 0 176 847 and 242 524. They preferably consist of two nonwovens, for example a glass fiber mat and a polyester fiber mat, which are connected to one another by needling. The needled laminate is then finally consolidated with a binder, acrylate-butadiene or acrylate-butadiene-styrene copolymers being generally used.

In der deutschen Offenlegungsschrift 26 19 087 werden z.B. für Polyesterspinnvliese Bindemittel beschrieben, bestehend aus einem Acrylat-Butadien-Styrol-Copolymerisat mit einem Zusatz von 5 bis 30 Gew.-% eines Melamin-Formaldehyd-­Vorkondensats.In German Offenlegungsschrift 26 19 087 e.g. described for polyester spunbonded binders, consisting of an acrylate-butadiene-styrene copolymer with an addition of 5 to 30 wt .-% of a melamine-formaldehyde precondensate.

Diese bekannten Bindemittel sind im Hinblick auf die textiltechnologischen Daten wie Festigkeit, Weiterreißfestigkeit usw optimiert, ihr Brandverhalten war jedoch bisher nur von geringem Interesse. Die aus mit diesen Bindemittelsystemen verfestigten Schichtstoffen hergestellten Bitumenschweißbahnen sind daher nur bedingt brandhemmend im Sinne der DIN 4107, Teil 7.These known binders have been optimized with regard to textile technology data such as strength, tear propagation resistance etc., however, their fire behavior has so far been of little interest. The bituminous welding sheets made from laminates consolidated with these binder systems are therefore only fire-retardant to a limited extent within the meaning of DIN 4107, Part 7.

Aus der deutschen Auslegeschrift 11 49 688 ist ein Verfahren zur Herstellung flammfester Vliesstoffe bekannt. Bei diesem Verfahren wird ein Flammschutzmittel gleichzeitig mit dem Bindemittel auf das Vlies aufgebracht. In einem der Beispiele dieser Druckschrift wird als Flammschutzmittel Tetrahydrophosphoniumchlorid eingesetzt, das gemeinsam mit einem Bindersystem aus Naturkautschuklatex und einem Melamin-Formaldehyd-Vorkondensat appliziert wird. Die Nachverfestigung des Vlieses erfolgt ebenfalls mit einem Melamin-Formaldehyd-Vorkondensat.A method for producing flame-retardant nonwovens is known from German patent specification 11 49 688. In this process, a flame retardant is applied to the nonwoven at the same time as the binder. In one of the examples in this publication, tetrahydrophosphonium chloride is used as the flame retardant, which is applied together with a binder system composed of natural rubber latex and a melamine-formaldehyde precondensate. The fleece is also solidified with a melamine-formaldehyde precondensate.

Die so ausgerüsteten Vliese sind jedoch für die Herstellung von nach DIN 4107, Teil 7 flammfesten bitmunierten Dach- und Dichtungsbahnen schlecht geeignet, da sie für diesen Zweck eine sehr hohe Menge von Flammschutzmitteln z.B. Antimontrioxid oder Phosphorverbindungen enthalten müssen. Dieser hohe Anteil von Flammschutzmitteln führt zu einer sehr starken Herabsetzung der Flexibilität der Vliese, so daß sie in dieser Hinsicht den Anforderungen zur Herstellung von Dach- und Dichtungsbahnen nicht mehr genügen.However, the nonwovens equipped in this way are poorly suited for the production of flame-retardant bitmunised roofing and waterproofing membranes in accordance with DIN 4107, Part 7, since for this purpose they must contain a very large amount of flame retardants, for example antimony trioxide or phosphorus compounds. This high proportion of flame retardants leads to a very strong reduction in the flexibility of the nonwovens, so that in this respect they no longer meet the requirements for the production of roofing and waterproofing membranes.

Die vorliegende Erfindung betrifft nun eine Trägerbahn zur Herstellung von Dach- und Dichtungsbahnen, die die Nachteile der bekannten Materialien nicht aufweist, in welcher vielmehr hohe mechanische Stabilität auch bei erhöhten Temperaturen mit sehr gutem Brandverhalten kombiniert ist.The present invention now relates to a carrier sheet for the production of roofing and sealing sheets which does not have the disadvantages of the known materials, in which high mechanical stability is combined with very good fire behavior even at elevated temperatures.

Die erfindungsgemäße Trägerbahn besteht aus einer Glasfasermatte und einer Hatte aus Synthesefasern, die miteinander vernadelt und die mit einem polymerisatfreien formaldehydarmen Melamin-Formaldehyd-Vorkondensat endverfestigt sind. Die in der erfindungsgemäßen Trägerbahn enthaltene Glasfasermatte kann in üblicher Weise mit den üblichen Bindern, d.h. meist Polymerisatbindern oder auch Melaminharzen vorverfestigt sein. Wegen der hohen Bindekraft der erfindungsgemäß eingesetzten formaldehydarmen Melamin-Formaldehyd-Vorkondensate ist es jedoch möglich, den für die Vorverfestigung des Glasvlieses benutzten Binderanteil deutlich zu senken, ohne daß die Endfestigkeit der erfindungsgemäßen Trägerbahn unzulässig reduziert wird.The carrier web according to the invention consists of a glass fiber mat and a hat made of synthetic fibers, which are needled together and which are finally consolidated with a polymer-free, low-formaldehyde melamine-formaldehyde precondensate. The glass fiber mat contained in the carrier web according to the invention can in the usual way with the usual binders, i.e. usually polymer binders or melamine resins are pre-consolidated. However, because of the high binding power of the low-formaldehyde melamine-formaldehyde precondensates used according to the invention, it is possible to significantly reduce the proportion of binder used for the pre-consolidation of the glass nonwoven without the final strength of the carrier web according to the invention being unduly reduced.

Das in der erfindungsgemäßen Trägerbahn enthaltene Synthesefaservlies kann aus allen Synthesefasertypen, die eine ausreichende Festigkeit haben, hergestellt sein. In Betracht kommen beispielsweise aliphatische und aromatische Polyamide, Polyacrylnitril und insbesondere Polyesterfasern. Zweckmäßigerweise werden dabei solche Fasertypen eingesetzt, die eine hohe Festigkeit, hohen Modul und einen niedrigen Hitzeschrumpf aufweisen, damit bei der Weiterverarbeitung zu Dach- und Dichtungsbahnen die Dimension der Trägerbahn konstant bleibt. Besonders bevorzugtes Synthesefasermaterial besteht aus Polyethylenterephthalat, insbesondere den hochfesten und schrumpfarmen Typen. Es ist im Prinzip auch möglich, aber nicht unbedingt erforderlich, daß das Synthesefaserylies aus schwer brennbaren Polyestern besteht. Beispiele für handelsübliche Synthesefasern, aus denen das Synthesefaservlies aufgebaut sein kann, sind (R)Trevira, insbesondere die hochfesten Typen und die schwer brennbare Type (R)Trevira CS.The synthetic fiber fleece contained in the carrier web according to the invention can be made from all types of synthetic fibers which have sufficient strength. For example, aliphatic and aromatic polyamides, polyacrylonitrile and in particular polyester fibers are suitable. It is expedient to use fiber types that have high strength, high modulus and low heat shrinkage, so that the dimension of the carrier web remains constant during further processing to form roofing and waterproofing membranes. A particularly preferred synthetic fiber material consists of polyethylene terephthalate, especially the high-strength and low-shrink types. In principle, it is also possible, but not absolutely necessary, that the synthetic fiberylies consist of flame-resistant polyesters. Examples of commercially available synthetic fibers from which the Synthetic fiber fleece can be constructed are (R) Trevira, in particular the high-strength types and the flame-retardant type (R) Trevira CS.

Das Synthesefaservlies kann aus Stapelfasern, zweckmäßigerweise mit Schnittlängen zwischen 1 und 100 mm oder aus Endlosfasern aufgebaut sein. Besonders bevorzugt sind Wirrvliese aus Endlosfasern, insbesondere Typen, die durch einen Kalandrierungsprozeß eine gewisse Vorverfestigung erfahren haben, wie z.B. die sogenannten Spunbonds.The synthetic fiber fleece can be constructed from staple fibers, advantageously with cutting lengths between 1 and 100 mm, or from continuous fibers. Tangled nonwovens made from continuous fibers are particularly preferred, in particular types which have undergone a certain degree of pre-consolidation through a calendering process, such as e.g. the so-called spunbonds.

Das formaldehydarme Melamin-Formaldehyd-Vorkondensat, mit dem die erfindungsgemäße Trägerbahn endverfestigt ist, hat ein Molverhältnis von Melamin zu Formaldehyd von 1:1,0 bis 1:3,5, vorzugsweise 1:1,2 bis 1:3. Von diesem formaldehydarmen Melamin-Formaldehyd-Vorkondensaten sind solche bevorzugt, die teilverethert und/oder sulfamatmodifiziert sind. Die teilveretherten Vorkondensate sind mit niederen Alkanolen, d.h. solchen mit 1 bis 4 Kohlenstoffatomen, insbesondere aber mit Methanol teilverethert. Der Veretherungsgrad der teilveretherten Vorkondensate ist dadurch gekennzeichnet, daß sie pro Mol Formaldehyd 0,2 bis 0,85, vorzugsweise 0,6 bis 0,8 Mol Ethergruppen aufweisen. Besonders bevorzugte formaldehydarme teilveretherte Melamin-Formaldehyd-Vorkondensate haben ein Molverhältnis von Melamin zu Formaldehyd von 1:2 bis 1:3 und weisen pro Mol Formaldehyd 0,6 bis 0,8 Mol Methylethergruppen auf. Sulfamatmodifizierte formaldehydarme Melamin-Formaldehyd-Vorkondensate, mit denen die erfindungsgemäße Trägerbahn endverfestigt sein kann, enthalten, bezogen auf Festharz, 1 bis 20 Gew.-%, vorzugsweise 5 bis 15 Gew.-% Sulfamat, gerechnet als Natriumsulfamat. Besonders bevorzugte sulfamatmodifizierte Melamin-Formaldehyd-Vorkondensate haben ein Molverhältnis Melamin zu Formaldehyd von 1:1,2 bis 1:2 und weisen, bezogen auf Festharz 5 bis 15 Gew.-% Sulfamat auf, gerechnet als Natriumsulfamat.The low-formaldehyde melamine-formaldehyde precondensate with which the carrier web according to the invention is finally consolidated has a molar ratio of melamine to formaldehyde of 1: 1.0 to 1: 3.5, preferably 1: 1.2 to 1: 3. Of these low-formaldehyde melamine-formaldehyde precondensates, preference is given to those which are partially etherified and / or modified with sulfamate. The partially etherified precondensates are partially etherified with lower alkanols, ie those with 1 to 4 carbon atoms, but especially with methanol. The degree of etherification of the partially etherified precondensates is characterized in that they have 0.2 to 0.85, preferably 0.6 to 0.8, mol of ether groups per mole of formaldehyde. Particularly preferred low-formaldehyde partially etherified melamine-formaldehyde precondensates have a molar ratio of melamine to formaldehyde of 1: 2 to 1: 3 and have 0.6 to 0.8 mol of methyl ether groups per mol of formaldehyde. Sulfamate-modified low-formaldehyde melamine-formaldehyde precondensates, with which the carrier web according to the invention can be finally consolidated, contain, based on solid resin, 1 to 20% by weight, preferably 5 to 15% by weight, of sulfamate, calculated as sodium sulfamate. Particularly preferred sulfamate-modified melamine-formaldehyde precondensates have a molar ratio of melamine to formaldehyde of 1: 1.2 to 1: 2 and, based on solid resin, have 5 to 15% by weight sulfamate, calculated as sodium sulfamate.

Für spezielle Einsatzgebiete kann es zweckmäßig sein, wenn das in der erfindungsgemäßen Trägerbahn enthaltene Melamin-­Formaldehyd-Vorkondensat zusätzlich geringe Menge, d.h. ca. 1 bis 5 Gew.-% bezogen auf Festharz, weitere Modifizierungsmittel, insbesondere die Plastizität steigernde Modifizierungsmittel enthält, solange dadurch die erforderliche Schwerbrennbarkeit nicht in unvertretbarem Maß herabgesetzt wird. Plastifizierende Zusätze dieser Art sind z.B. Di- und Triethylenglykol sowie deren Ether oder Polyethylenglykole mit Molgewichten bis zu 2000. Besonders bevorzugt sind jedoch erfindungsgemäße Trägerbahnen, die mit einem Melamin-Formaldehyd-Vorkondensat ohne zusätzliche plastifizierende Modifizierungsmittel endverfestigt sind.For special fields of application, it may be expedient if the melamine-formaldehyde precondensate contained in the carrier web according to the invention additionally contains a small amount, i.e. 1 to 5% by weight, based on solid resin, contains further modifying agents, in particular modifying agents which increase plasticity, as long as this does not unduly reduce the necessary flame resistance. Plasticizing additives of this type are e.g. Di- and triethylene glycol and their ethers or polyethylene glycols with molecular weights up to 2000. However, particular preference is given to carrier webs according to the invention which are solidified with a melamine-formaldehyde precondensate without additional plasticizing modifiers.

Besonders bevorzugt sind auch solche erfindungsgemäßen Trägerbahnen, die eine Kombination mehrerer bevorzugter Merkmale aufweisen.Carrier webs according to the invention which have a combination of several preferred features are also particularly preferred.

Die erfindungsgemäße Trägerbahn zeigt gegenüber bekannten Trägerbahnen den Vorteil, daß sie bei einer der Weiterverarbeitung sehr entgegenkommenden hohen Flexibilität ein verbessertes Brandverhalten zeigt. Sie ist in dieser Hinsicht sowohl den aus der DE-AS 1 149 688 bekannten als auch den unter Einsatz eines Bindemittels gemäß DE-OS 26 19 087 hergestellten Vliesmaterialien erheblich überlegen. Auch die mechanische Belastbarkeit der erfindungsgemäßen Trägerbahn unter Wärmeeinwirkung (Temperaturbereich z.B. 180°C), wie sie bei der Weiterverarbeitung zu Dach- und Dichtungsbahnen auftritt, ist wesentlich verbessert. Das gleiche gilt für die Weiterreißfestigkeit der erfindungsgemäßen Trägerbahn, die gegenüber Trägerbahnen, die mit Polyacrylatbindern endverfestigt sind, um ca. 25 % gesteigert ist.The carrier web according to the invention has the advantage over known carrier webs that it exhibits improved fire behavior with a high degree of flexibility which is very accommodating for further processing. In this respect, it is considerably superior to both the nonwoven materials known from DE-AS 1 149 688 and the nonwoven materials produced using a binder according to DE-OS 26 19 087. The mechanical load-bearing capacity of the carrier web according to the invention under the influence of heat (temperature range, e.g. 180 ° C.), as occurs during further processing into roofing and waterproofing membranes, has also been significantly improved. The same applies to the tear propagation resistance of the carrier web according to the invention, which is increased by approximately 25% compared to carrier webs which are finally consolidated with polyacrylate binders.

Zur Herstellung der oben beschriebenen erfindungsgemäßen Trägerbahn wird eins der oben spezifizierten Synthesefaservliese mit einem gegebenenfalls vorverfestigten Glasfaservlies vernadelt und anschließend mit einem wäßrigen Melamin-Formaldehyd-Vorkondensat der oben angegebenen Spezifikation, dem zweckmäßigerweise ca. 0,5 bis 3 % eines bekannten Härters, z.B. einem Härter auf Basis von p-Toluolsulfonsäure zugesetzt worden ist, durch Besprühen, Pflatschen oder vorzugsweise Tauchen imprägniert auf die erforderliche Harzaufnahme von 5 bis 40 vorzugsweise 15 bis 30 Gew.-% bezogen auf unimprägniertes Material abgequetscht, gegebenenfalls zwischengetrocknet und anschließend in einem Wärmeofen, in der Regel bei Temperaturen zwischen 80 bis 200, vorzugsweise 120 bis 180°C, im Verlaufe von 5 bis 30 Minuten ausgehärtet. Auch die Herstellung der erfindungsgemäßen Trägerbahn ist Gegenstand der vorliegenden Patentanmeldung.To produce the carrier web according to the invention described above, one of the above specified is used Synthetic fiber nonwovens needled with an optionally pre-consolidated glass fiber fleece and then with an aqueous melamine-formaldehyde precondensate of the above-mentioned specification, to which approximately 0.5 to 3% of a known hardener, for example a hardener based on p-toluenesulfonic acid, has advantageously been added Spraying, splashing or, preferably, dipping impregnated to the required resin absorption of 5 to 40, preferably 15 to 30,% by weight, based on unimpregnated material, optionally squeezed out and then dried in a heating oven, generally at temperatures between 80 to 200, preferably 120 to 180 ° C, hardened in the course of 5 to 30 minutes. The production of the carrier web according to the invention is also the subject of the present patent application.

Die erfindungsgemäße Trägerbahn kann für sehr unterschiedliche Zwecke mit besonderem Vorteil eingesetzt werden. Sie kann z.B. aufgrund ihrer Schwerbrennbarkeit als Dekorationsträger eingesetzt werden. Besonders bevorzugt ist ihr Einsatz als Trägermaterial für bituminierte Dach- und Dichtungsbahnen.The carrier web according to the invention can be used for very different purposes with particular advantage. It can e.g. can be used as a decoration support due to their flame retardancy. Their use as a carrier material for bituminized roofing and waterproofing membranes is particularly preferred.

Der erfindungsgemäße Einsatz der oben spezifizierten formaldehydarmen Melamin-Formaldehyd-Vorkondensate bietet auch Vorteile bei der Herstellung der erfindungsgemäßen Trägerbahn: Es können nämlich Glasvliese mit relativ niedrigem Bindemittelgehalt verwendet werden. Da bei niedrigem Bindemittelgehalt der Charakter des Bindemittels eine geringere Rolle spielt, können z.B. preiswertere Glasvliese mit niedrigerem Bindemittelgehalt, die nicht schwer brennbar sein müssen, verwendet werden.The use according to the invention of the low-formaldehyde melamine-formaldehyde precondensates specified above also offers advantages in the production of the carrier web according to the invention: namely, glass nonwovens with a relatively low binder content can be used. Since the character of the binder plays a minor role when the binder content is low, e.g. cheaper glass fleeces with a lower binder content, which do not have to be flame-retardant, can be used.

Claims (15)

1. Trägerbahn aus flächenförmigem Fasermaterial bestehend aus einer Glasfasermatte und einer Matte aus Synthesefasern, die miteinander vernadelt und die mit einem polymerisatfreien, formaldehydarmen Melamin-­Formaldehyd-Vorkondensat endverfestigt sind.1. Carrier web made of sheet-like fiber material consisting of a glass fiber mat and a mat made of synthetic fibers, which are needled together and which are finally consolidated with a polymer-free, low-formaldehyde melamine-formaldehyde precondensate. 2. Trägerbahn gemäß Anspruch 1, dadurch gekennzeichnet, daß die Synthesefasermatte aus Polyesterfasern besteht.2. Carrier web according to claim 1, characterized in that the synthetic fiber mat consists of polyester fibers. 3. Trägerbahn gemäß mindestens einem der Ansprüche 1 und 2, dadurch gekennzeichnet, daß die Synthesefasermatte ein Spunbond ist.3. Carrier web according to at least one of claims 1 and 2, characterized in that the synthetic fiber mat is a spun bond. 4. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß sie mit einem Melamin-­Formaldehyd-Vorkondensat endverfestigt ist, das ein Molverhältnis von Melamin zu Formaldehyd von 1:1,0 bis 1:3,5 aufweist.4. Carrier web according to at least one of claims 1 to 3, characterized in that it is end-solidified with a melamine-formaldehyde precondensate which has a molar ratio of melamine to formaldehyde of 1: 1.0 to 1: 3.5. 5. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß sie mit einem Melamin-­Formaldehyd-Vorkondensat endverfestigt ist, das teilverethert und/oder sulfamatmodifiziert ist.5. Carrier web according to at least one of claims 1 to 4, characterized in that it is end-solidified with a melamine-formaldehyde precondensate which is partially etherified and / or sulfamate-modified. 6. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, daß sie mit einem Melamin-­Formaldehyd-Vorkondensat endverfestigt ist, das entweder teilverethert oder sulfamatmodifiziert ist.6. Carrier web according to at least one of claims 1 to 5, characterized in that it is end-solidified with a melamine-formaldehyde precondensate which is either partially etherified or sulfamate-modified. 7. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß sie mit einem Melamin-­Formaldehyd-Vorkondensdat endverfestigt ist, das mit niederen Alkoholen teilverethert ist.7. Carrier web according to at least one of claims 1 to 6, characterized in that it is end-solidified with a melamine-formaldehyde precondensate which is partially etherified with lower alcohols. 8. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß sie mit einem teilveretherten Melamin-Formaldehyd-Vorkondensat endverfestigt ist, das pro Mol Formaldehyd 0,2 bis 0,85 Mol Alkanethergruppen aufweist.8. Carrier web according to at least one of claims 1 to 7, characterized in that it is end-solidified with a partially etherified melamine-formaldehyde precondensate which has 0.2 to 0.85 mol of alkane ether groups per mole of formaldehyde. 9. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 8, dadurch gekennzeichenet, daß sie mit einem Melamin-­Formaldehyd-Vorkondensat endverfestigt ist, das ein Molverhältnis von Melamin zu Formaldehyd von 1:2 bis 1:3 aufweist und pro Mol Formaldehyd 0,6 bis 0,8 Mol Methylethergruppen aufweist.9. A carrier web according to at least one of claims 1 to 8, characterized in that it is end-solidified with a melamine-formaldehyde precondensate which has a molar ratio of melamine to formaldehyde of 1: 2 to 1: 3 and 0.6 per mole of formaldehyde has up to 0.8 mol of methyl ether groups. 10. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß sie mit einem Melamin-­Formaldehyd-Vorkondensat endverfestigt ist, welches, bezogen auf Festharz, 1 bis 20 Gew.-% Sulfamat, gerechnet als Natriumsulfamat, enthält.10. Carrier web according to at least one of claims 1 to 6, characterized in that it is end-solidified with a melamine-formaldehyde precondensate which, based on solid resin, contains 1 to 20% by weight sulfamate, calculated as sodium sulfamate. 11. Trägerbahn gemäß mindestens einem der Ansprüche 1 bis 6 und 10, dadurch gekennzeichnet, daß sie mit einem Melamin-Formaldehyd-Vorkondensat endverfestigt ist, welches ein Molverhältnis von Melamin zu Formaldehyd von 1:1,2 bis 1:2 hat und bezogen auf Festharz, 5 bis 15 Gew.-% Sulfamat, gerechnet als Natriumsulfamat enthält.11. A carrier web according to at least one of claims 1 to 6 and 10, characterized in that it is end-solidified with a melamine-formaldehyde precondensate which has a molar ratio of melamine to formaldehyde of 1: 1.2 to 1: 2 and based on Solid resin, 5 to 15 wt .-% sulfamate, calculated as sodium sulfamate contains. 12. Verfahren zur Herstellung der Trägerbahn des Anspruchs 1 durch Vernadeln eines Synthesefaservlieses mit einem, gegebenenfalls vorverfestigten Glasfaservlies und anschließende Endverfestigung, dadurch gekennzeichnet, daß das zweischichtige Gebilde mit der im wesentlichen wäßrigen Lösung eines formaldehydarmen Melamin-Formaldehyd-Vorkondensats, der ca. 0,5 bis 5 Gew.-% eines üblichen Härters zugesetzt wurden, imprägniert, auf eine Harzaufnahme, bezogen auf unbeharztes Material, von 5 bis 40 Gew.-% abgequetscht und anschließend bei erhöhter Temperatur ausgehärtet wird.12. A process for producing the carrier web of claim 1 by needling a synthetic fiber fleece with an optionally pre-consolidated glass fiber fleece and subsequent final consolidation, characterized in that the two-layer structure with the essentially aqueous solution of a low-formaldehyde melamine-formaldehyde precondensate, the approx. 5 to 5 wt .-% of a conventional hardener were added, impregnated, based on a resin absorption non-resinous material, squeezed from 5 to 40 wt .-% and then cured at elevated temperature. 13. Verfahren gemäß Ansprcuh 12, dadurch gekennzeichnet, daß ein Melamin-Formaldehyd-Vorkondensat eingesetzt wird, welches teilverthert und/oder sulfamatmodifiziert ist.13. The method according to Ansprcuh 12, characterized in that a melamine-formaldehyde precondensate is used which is partially hardened and / or sulfamate-modified. 14. Verfahren gemäß mindestens einem der Ansprüche 12 und 13, dadurch gekennzeichnet, daß das Melamin-Formaldehyd-­Vorkondensat entweder teilverethert oder sulfamatmodifiziert ist.14. The method according to at least one of claims 12 and 13, characterized in that the melamine-formaldehyde precondensate is either partially etherified or sulfamate-modified. 15. Verwendung der Trägerbahn des Anspruchs 1 zur Herstellung von bituminierten Dach- und Dichtungsbahnen.15. Use of the carrier sheet of claim 1 for the production of bituminized roofing and sealing sheets.
EP90100667A 1989-01-17 1990-01-13 Flame-resistant carrier web for bitumen webs, and process for producing the same Expired - Lifetime EP0379100B1 (en)

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NO900231L (en) 1990-07-18
DE59009035D1 (en) 1995-06-14
NO900231D0 (en) 1990-01-16
US5171629A (en) 1992-12-15
ATE122412T1 (en) 1995-05-15
EP0379100B1 (en) 1995-05-10
FI900214A0 (en) 1990-01-15
NO173515C (en) 1993-12-22
AU4796790A (en) 1990-07-26
ZA90284B (en) 1990-11-28
NO173515B (en) 1993-09-13
JPH02233240A (en) 1990-09-14
DE3901152A1 (en) 1990-07-19
CA2007882A1 (en) 1990-07-17

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