DE102005048442A1 - Laminate, useful as a component in building products, medical products or safety clothings, comprises a first- and second fleece from thermoplastic polyolefin material and a prefabricated, stretched lattice - Google Patents

Abstract

Laminate comprises at least a first- and second fleece from thermoplastic polyolefin material and a prefabricated, stretched lattice that is arranged between the two fleeces for stabilization, where at least one of the fleece forms an exterior of the laminate and the lattice is firmly connected with at least one of the two fleeces. Independent claims are included for: (1) a plant for the production of the laminate, comprising a stretching unit, which is downstream at least to a fleece production unit and a film supply unit, and a bonding unit that is arranged between the stretching unit and the fleece production unit and the lattice insert; and (2) the preparation of the laminate comprising connecting the lattice with the fleece, before the laminate is stretched.

Description

The The present invention relates to a laminate having at least a first one and a second nonwoven each made of thermoplastic polyolefin material consist, between the two fleeces arranged a grid is.

nonwovens have the advantage that they vary depending on the application can be configured. In general, the application only limits the used Materials and their properties set.

task The present invention is for nonwoven fabrics of polyolefin materials to open a broader application base.

These Task is with a laminate with the features of the claim 1, with a plant for producing a laminate with the features of claim 24 and with a method for producing a Laminate with the features of claim 30. Further advantageous Embodiments and developments are specified in the respective subclaims.

It becomes a laminate with at least a first and a second nonwoven proposed, which are each made of thermoplastic polyolefin material between the two nonwovens a prefabricated, stretched grid is arranged for stabilization, wherein at least one of the fleeces an outside of the laminate forms and the grid at least with one of the two Nonwovens is firmly connected. The arrangement of a grid between the first and second webs allow use of the laminate especially in areas where a mechanical strength a nonwoven as such does not have the necessary strength guarantee would. To achieve high strength values, the grid becomes, for example at least in CD direction vorverstreckt. Preferably, the grid is also pre-stretched in MD direction. According to another embodiment it is provided that the first and the second fleece, preferably the entire laminate is stretched together with the grid. The Grid material preferably comprises a polymer. By stretching This polymer material succeeds to the actual strength an additional To be able to achieve strength by alignment of the polymer chains.

A Another embodiment provides that the grid in the CD direction and is stretched differently in the MD direction. To this Way the laminate has a strength that is higher in one direction as in a different direction. According to one additional From design is provided that the grid has different side lengths. According to one Embodiment is provided that a length of a grid component is larger as a width of a grid component. As grid components In particular, rectangles should be understood here, all together make the grid. Preferably, therefore, the grid has rectangular shapes on, which are connected at intersections among themselves. By prefabrication of the grid is allowed, possibly additional Characteristics imprinted could be. For example, the grid may be prior to incorporation into the laminate be pre-stretched. In addition, the grid may additionally be provided with a binder, For example, be equipped with a binding adhesive. Also can For example, the grid may have a core-shell structure. For example For example, a core has a different material than the cladding. According to one Embodiment is provided that the jacket is a polyolefin material having. The core, on the other hand, can be made from another, for example Polyolefin material or polymer or a completely different Material, such as a metal exist. It is preferred if the grid is exclusive made of polypropylene, polyethylene or a mixture of polypropylene and polyethylene.

According to one Embodiment, the grid is stretched so that the weight of the grid by at least a factor of 1.5, preferably at least 2, before stretching is larger as after stretching.

It has proven to be advantageous when the mesh material is a polymer comprising, the component of the thermoplastic material of at least one of the two fleeces is. This allows for improved binding between the grid and this fleece. Preferably, the grid material a surface comprising a polymer having both nonwovens each.

A improved bonding effect between grid and nonwoven results, if at least the first nonwoven consists of bicomponent staple fibers. For example, the first nonwoven has a higher adhesion to the grid as the second fleece. The second nonwoven consists according to a Design either of polypropylene or polyethylene. For example the second fleece is a spunbonded fabric. It can, however, also be a carded one Nonwoven, a meltblown or other nonwoven material.

A Another embodiment of the laminate provides that this one Film which is permeable to water vapor and impermeable to water. For example, the film is a polymer that absorbs water and desorbed again. According to one Another embodiment provides that the film is microporous. Especially the film is also like all other components of the laminate mitverstreckt. Another embodiment provides that the movie obtained by the stretching of the laminate its microporosity Has. According to one Further training is provided that the film has an outside of the laminate. For example, it is provided that a bond the film is provided on a nonwoven. A preferred laminate construction arises when the grid is arranged between the two nonwovens is through and outside the fleece and another outside formed by the film. Another embodiment provides that the film is arranged inside the laminate. Here can additionally a fleece is arranged between the film and the grid be while the outer surfaces of the Laminates are each formed by nonwovens.

For a connection, the permanently under stretching between the individual components of the laminate remains, the use of a grid of Polyolefin proven. For example, the grid is made of polypropylene. The individual lattice parts are strands, which are connected to each other at the respective nodes. According to one Another embodiment provides that the grid of a stamped material. This allows a particularly high integrity of the grid material. According to one Another embodiment provides that the film of thermoplastic Material consists, whose melting point is lower than the one of the grid. This allows in particular that the grid and a Nonwoven are thermobonded with each other, wherein the grid during the thermobonding not hurt the movie. Preferably, this acts between the grid and the film disposed nonwoven as a kind of buffer material. This takes the effective pressure of, for example, embossing points of a stamping calender without destroying the movie. Furthermore prevented the fleece a heat conduction in the movie. This allows, for example, that the embossing calender can be driven at a temperature above one for the film harmful Temperature is. It is preferably provided that the used Temperature range for embossing of the laminate on the film is less than 80 ° C.

A Further embodiment of the laminate provides that the first nonwoven a basis weight has that by at least a factor of 2 is greater than the basis weight of the second web. The differences in basis weight are preferred thus the fleeces certain functionalities. While the first fleece with the larger basis weight preferably an outer surface of the Laminate is the second nonwoven with the lower basis weight directly connected to the film and provides a protection for the film Grid down. The second web is preferably between the grid and the film and serves as a link for both. According to one Embodiment is provided that the second web at least at the surface Polyethylene has. This serves to tie on the one hand the grid, on the other hand also to tie up the film. Because the polyethylene melts earlier as for example a polypropylene used in the grid or a polypropylene in the film, this at the Thermobondingschritt both layers have not changed in their basic structure.

It is preferred if the first web has more than 30 g / m ² basis weight and the second web has less than 15 g / m ² basis weight. It is particularly preferred if the total weight of the laminate is less than 70 g / m ² . A further preferred construction of the laminate provides that a bicomponent spunbonded nonwoven fabric as first and / or second nonwoven fabric comprises a core of polypropylene and a jacket of polyethylene. It is also possible that the laminate has a second nonwoven, which is a polyethylene spunbonded nonwoven. According to a further development, it is provided that the bicomponent spunbonded nonwoven has a core of polypropylene with a proportion of polyethylene. In this case, the polyethylene can serve for improved drawability of the bicomponent spunbonded nonwoven. In turn, the core of polypropylene may have one or more polypropylene components, preferably having different MFI values. In this way, a strength of the spunbonded fabric and thus of the laminate can also be improved.

Preferably, it has been found that when the laminate is provided with at least one bicomponent spunbonded nonwoven having polypropylene in the core, the core being at least 90% by weight of the bicompo spunbond core. It is particularly preferred if the core has at least 95% by weight of polypropylene. According to one embodiment, it is provided that the proportion of polyethylene in the core is less than 4%.

Especially high strengths can be achieved if the core-to-shell ratio at least 50:50 to 70:30 with a used bicomponent spunbond is. According to one Another embodiment provides that the core-sheath ratio preferably at least 85:15 or more, especially at least 90:10.

A preferred application of such a laminate is in a construction product or as a construction product itself. Here, the construction product may be a roofing membrane, a roof underlay, a roofing membrane, a wall covering, a vapor barrier, a lining or any other field of application in the context of civil engineering th. The construction product may be permeable to water vapor and impermeable to water according to a further development. In addition, it can be provided in a development that the construction product is also permeable to air. Possible physical values for the different applications go, for example, from the EP 1 400 348 , from the GB 12 41 578 , from the EP 740 027 , from the EP 708 212 and / or from the EP 570 215 to which reference is made in this regard in the context of the disclosure.

Furthermore, it is provided that the construction product with grid material has at least the following values at least individually, partially or in total, for example: weight of the layer material: between 70 g / m ² and 130 g / m ² (according to DIN 53854), a tensile strength in MD of at least 80 N / 5 cm (after EN 29073, T3 ), a tensile strength in CD of at least 100 N / 5 cm (acc EN 29073, T3 ), a sheet material adhesion of at least 1 N (according to cm 162-A), an air permeability at 2 mbar of more than 1100 l / m ² sec. (according to DIN EN ISO 9237) and / or a water column of at least 30 cm (according to DIN EN 20881). According to a preferred embodiment, the water column is over 100 cm. The values shown in each case can be achieved individually as well as in total.

Another example provides an embodiment of an extendable grid made of a polyolefin polymer, in particular polyethylene, which is also used in a construction product or in another product. For example, prior to stretching, the grid has a weight of 32 g / m ² . After stretching, the weight of the grid is lowered to about 12 g / m ² . This results in the following mechanical data:

Preferably results in an improvement in the tensile strength of at least 10% in CD direction, preferably of at least 20% in the MD direction, if a polyolefin mesh, in particular a polyethylene mesh stretched in the laminate is present. Especially the nail sting tear resistance is increased in CD as well as in MD by at least 35%.

According to one Another embodiment provides that the laminate component a medicinal product or a medicinal product itself. Medical Products can For example, surgical covers, duvet covers, bandages, protective packaging in the Medical field, drapes, Plasters as well as components of clothing. By the particularly high strength of the laminate allows this to be used as well takes place on tensile or compression-stressed medical products. Preferably the laminate is able to be virus-impermeable as well as impermeable to blood or To be blood components. Values for this as well as test methods go from US 2003/124324, referred to in this disclosure referenced in this regard becomes.

A further embodiment provides that the laminate is part of a protective clothing. For example, all protective clothing may consist of the laminate. For this purpose, it should be provided that the laminate is preferably liquid impermeable, but water vapor permeable. As a result, the wearer of the protective clothing can pass on the secreted perspiration at least partially outwards through the protective clothing. The reinforcement allows, in particular, protective clothing made of the laminate can be used, which can also be used in areas where it depends on the special tear resistance of protective clothing. Such a laminate has an advantage over protective suits made from pure film-nonwoven composites.

According to one Another idea of the invention is a plant for the production a laminate, in particular as described above, proposed wherein the plant has a drawing unit, the at least one Fleece-generating unit and a grid feed downstream, and a bonding unit between the stretching unit and the nonwoven forming unit and the grid feed arranged arranged. The bonding unit is preferably a thermal bonding unit, for example, with at least one embossing calender. Furthermore, can the bonding unit in addition as well as separately or even instead of the Thermobondiereinheit connecting means such as hydroentanglement, ultrasound, gluing, needling or the like. The stretching unit is preferably a combination of a drawing device in CD and a stretching device in the MD direction. The stretching device in the MD direction is the drawing device in the CD direction preferably upstream. However, it can also be an integration of both in a single drawing device. The Nonwoven production unit is preferably a bicomponent spunbonded system. This preferably has a first extruder and a second Extruder, wherein the first extruder, for example, for the core material is designed. The second extruder is for example for the jacket material designed the bicomponent spunbonded. In addition to the use of Core-shell structures, however, are also the production of others Bicomponent structures in fibers possible, for example cake structures, eccentric or concentric core-shell structures, hollow fibers, so-called splittable fibers, as side-by-side fiber and / or as "Iceland in the sea "fiber.

A Further development provides that the fleece supply unit of the bonding unit is upstream. This allows in that the laminate is formed before reaching the bonding unit. Another embodiment provides that multiple bonding units are provided in the system. This allows, for example, that at least two layers are firmly joined together before a third Location supplied becomes. About that can out thereby different bonding methods in a laminate for use reach. This is in particular dependent on a diversity the materials used and the necessary purpose of the Laminate.

A preferred embodiment provides that the bonding unit a Smooth roller having an embossing roller across from is arranged. Preferably, the embossing of the embossing roll has less than 23% of one surface the embossing roll on. For example, the smooth roller and the film feed unit arranged such that a film from the Filmzuführeinheit directly on the smooth roller comes to concern. That way you can produce a laminate in which one side is particularly strong pronounced Verprägung having. The other side, however, is also with the others Layers of the laminate thermobonded. The embossment, however, is designed such that a property such as a water vapor permeability and impermeability, made by, for example, a microporosity of a film used, not so affected that the footage could no longer do its job.

A Another preferred embodiment of the system provides that as film supply a device is provided which is combined with a film production device. The film-making apparatus becomes the molten film material For example, stored directly on a fleece. A bond between this Fleece and the still molten thermoplastic material can by a subsequent pressing process, for example, by a smooth-roller calender. Farther it is possible, that a connection between the thermoplastic material of Films and that of the nonwoven is thereby improved that an electrostatic Unit is provided. about the electrostatic forces generated thereby becomes a special intimate Connection between the example applied directly to the nonwoven, achieved molten material of the film.

According to one Another idea of the invention is a process for the production a laminate having a first and a second nonwoven and a provided therebetween prefabricated grid, wherein the grid is at least bonded to a fleece before the laminate is stretched.

A further embodiment provides that the components of the laminate are stretched together. This allows the draw rate to be the same for the same components of the laminate. Another embodiment provides that the components of the laminate are stretched differently. This can be achieved, for example, by providing a plurality of stretching units. While some of the constituents of the laminate pass through one or more of the drafting units, one or more constituents of the laminate do Laminate this not. In addition, a stretching of the laminate or the individual components depends on the particular nature of the component. For example, while one component of the laminate is stretched to 50% of its maximum stretchability, another component of the laminate is stretched only to 20 to 30% of its maximum stretchability.

Preferably it is envisaged that a film will be laminated and stretched, which is heated to less than 80 ° C during a bonding step. This allows that a microporous Formed film whose microporosities in the subsequent bonding step, especially thermobonding step can not be closed again. In particular, this also allows the use of a film, for example made of polyethylene, the microporous is.

Further advantageous embodiments and developments and features will be explained in more detail in the following drawings. The illustrated there However, features are not limited to the individual embodiments. Much more can These features with other features of the drawing or be linked to other embodiments of the above description. Show it:

1 a schematic view of a first plant for the production of a proposed laminate,

2 a schematic view of a second system,

3 a schematic view of a third system,

4 a schematic view of a fourth plant,

5 a schematic view of a grid used,

6 a schematic view of a lattice punching machine,

7 a schematic view of a first laminate,

8th a schematic view of a second laminate and

9 a schematic view of a Thermobondierschrittes with a laminate, in particular as in 8th shown.

1 shows a schematic view of a first attachment 1 for the production of a laminate. From a grid feeder 2 , from a first nonwoven feeder 3 and a second nonwoven supply device 4 become a grid 5 , a first prefabricated fleece 6 and a second prefabricated fleece 7 to a first calender 8th guided. The first calender 8th serves as a thermobonding unit. From there, the Vorlaminat 9 to a first drawing device 10 led, which allows stretching in the MD direction. From the first drawing device 10 enters the pre-consolidated pre-laminate in one direction 9 now to a second drawing device 11 , By means of this is the prelaminate 9 now also stretched in CD direction. The finished, stretched laminate 12 can then be wound as well as cut at the same time or get directly into further processing.

The following are the same or similar components as those 1 provided with the same reference numerals.

2 shows a second attachment 13 for the production of a laminate. From the grid feeder 2 and the first nonwoven feeder 3 become the first fleece 6 and the grid 5 to the first calender 8th guided. There, both are thermobonded. A spunbonding device 14 , Preferably, a bicomponent spunbonding device is the first calender 8th downstream as a bonding unit. The spunbonding device 14 downstream is a second bonding unit 15 , preferably in turn a thermal bonding calender. From the second bonding unit 15 from the pre-laminate arrives 9 in the first drawing device 10 before putting it in the second drawing device 11 and finally as a finished stretched laminate 12 the second plant 13 to any other stations or a rewinding unit leaves. Further stations can effect, for example, impregnation of at least one of the two sides of the laminate. Furthermore, for example, refractory equipment, hydrophilic or hydrophobic equipment, Farbausrüs be applied, adhesives or the like.

3 shows a third attachment 16 , From the first fleece feeder 3 becomes the first fleece 6 as well as from the grid feed device 2 the grid 5 a first bonding unit 17 fed. The first bonding unit 17 downstream is the second web feed device 4 arranged, of which the second prefabricated fleece 7 a third bonding unit 18 is supplied. The third bonding unit 18 downstream is a Fllmzuführvorrichtung 19 arranged. This will be a movie 20 a fourth bonding unit 21 fed. The prelaminate thus produced thus has the first nonwoven 6 like the movie 20 each on the outside, before the respective stretching by the first drawing device 10 or second drawing device 11 he follows.

4 shows a schematic view of a fourth attachment 22 for the production of a laminate. From the first nonwoven feeder 3 becomes the first prefabricated fleece 6 to the first calender 8th guided. From the grid feeder 2 becomes the grid 5 first in MD via an additional drawing device 23 pre-stretched, before it also in the first calender 8th with the first prefabricated fleece 6 thermobonded. Subsequently, the second nonwoven feeder is used 4 the second prefabricated fleece 7 supplied and with the two previously supplied layers in the second calender 24 thermobonded. The second calender 24 Subordinate is a film production unit 25 , This has, for example, one or more extruders, which have one or more slot nozzles. The film can thus be one or more layers. Preferably, for better bonding of the molten thermoplastic film material to the prepared sheet material, an electrostatic unit is provided 26 assigned. By means of this it is possible to produce an improved bond between the nonwoven surface of the second prefabricated nonwoven and the thermoplastic material of the film. For example, this makes it possible that the thermoplastic material of the film can penetrate not only superficially on the fleece, but also in the fleece itself.

The electrostatic unit 26 downstream is, for example, a third calender 27 , about which the laminate in the first drawing device 10 is transferred under simultaneous pressing. For example, the third calender 27 two smooth rolls on, between which the prelaminate 9 is passed. From the first drawing device 19 For example, the prelaminate may continue to be fed into a fourth calender before entering the second drawing device 11 arrives.

5 shows a schematic view of the grid 5 , This preferably has in each case rectangular components whose length L and whose width B, however, are different according to one embodiment. For example, the ratio L to B may be between 1: 2 to 2: 1. The weight of the grid is preferably between 5 g / m ² up to 15 g / m ² . In addition to the arrangement of rectangular components, the grid can 5 also have polygonal components. Also, the grid components may be rounded, in particular circular. This can be produced in particular by stamped grids. Furthermore, trapezoidal, star-shaped as well as mixed forms of holes and hole geometries can be provided.

6 shows a schematic view of a punching device 29 where, for example, a movie 30 obtains a grid geometry characterized in that the grid surfaces to be formed remain and excess material through the punching device 29 is punched out.

7 shows a schematic view of a first laminate 31 with an upper fleece 32 and a lower fleece 33 , Between the two fleeces 32 . 33 is the grid 5 arranged. The lower fleece 33 has a lower basis weight than the upper nonwoven 32 ,

8th shows a schematic embodiment of a second laminate 34 on. The second laminate 34 includes the components of the first laminate 31 out 7 , In addition to the lower fleece 33 a liquid impermeable and vapor permeable film 35 arranged. This film as outer surface ensures the laminate a particularly high waterproofness.

9 shows a schematic view of the exemplary thermal bonding of the second laminate 34 , where the movie 35 on a smooth roller 36 to lie down while the top fleece 32 directly with a stamping calender 37 and its heated embossing surveys 38 is charged.

Claims (33)

Laminate comprising at least a first and a second nonwoven each of thermoplastic polyolefin material, wherein between the two nonwovens a prefabricated, stretched grid for stabilization is arranged, at least one of the nonwovens forms an outer side of the laminate and the grid at least with a the two nonwovens is firmly connected. Laminate according to claim 1, characterized in that the grid is stretched in the CD direction. Laminate according to claim 1 or 2, characterized that the laminate is stretched in the MD direction. Laminate according to one of the preceding claims, characterized in that the grid material comprises a polymer which Component of the thermoplastic material of at least one the two fleeces is. Laminate according to one of the preceding claims, characterized characterized in that the first non-woven of bicomponent staple fibers consists. Laminate according to one of the preceding claims, characterized in that the laminate has a film which is permeable to water vapor and waterproof is. Laminate according to claim 6, characterized that the film is microporous and stretched. Laminate according to claim 6 or 7, characterized that the film is an outside of the laminate. Laminate according to one of the preceding claims, characterized characterized in that the grid consists of polyolefin material. Laminate according to claim 6, 7 or 8, characterized that the film is made of thermoplastic polyolefin material, whose melting point is lower than that of the lattice. Laminate according to one of the preceding claims, characterized characterized in that the grid consists of a stamped material. Laminate according to one of the preceding claims, characterized characterized in that at least the grid and the nonwoven with each other are thermobonded. Laminate according to one of the preceding claims, characterized in that the first nonwoven has a weight per unit area at least the factor 2 is larger as the basis weight of the second web. Laminate according to claim 13, characterized in that the first web has more than 30 g / m ² basis weight and the second web has less than 15 g / m ² basis weight. Laminate according to one of the preceding claims, characterized characterized in that a bicomponent spunbonded nonwoven fabric of the laminate a core of predominantly Polypropylene and a jacket at least predominantly of polyethylene having. Laminate according to one of the preceding claims, characterized in that the second nonwoven is a spunbonded polyethylene is. Laminate according to claim 15, characterized in that that the bicomponent spunbonded a core of polypropylene with a proportion of polyethylene. Laminate according to claim 15 or 17, characterized the polypropylene in the core constitutes at least 90% by weight, in particular at least 95% by weight. Laminate according to claim 15, 17 or 18, characterized that the core-coat ratio at least 50:50 to 70:30. Laminate according to claim 15, 17 or 18, characterized that the core-coat ratio at least 80:20, preferably at least 85:15 or more. 21 Laminate according to one of the preceding claims, characterized that it is part of a construction product. Laminate according to one of the preceding claims, characterized characterized in that it is part of a medicinal product. Laminate according to one of the preceding claims, characterized characterized in that it is part of a protective clothing. Plant for producing a laminate according to one of the preceding claims, wherein the plant has a drawing unit, the at least one Fleece production unit and a film feeder is downstream, and a bonding unit between the stretching unit and the nonwoven forming unit and the grid feed is arranged. Plant according to claim 24, characterized the bonding unit is preceded by a nonwoven supply unit. Plant according to claim 24 or 25, characterized the bonding unit is preceded by a film feed unit. Installation according to claim 24, 25 or 26, characterized in that the bonding unit has a smooth roller which is an embossing roller across from is arranged. Plant according to claim 27, characterized that an imprint the embossing roll less than 23% of a surface the embossing roll claimed. Plant according to claim 27, characterized that the smooth roller and the film supply unit to each other arranged that a film from the film feed unit directly on the Smooth roller comes to the concern. Process for producing a laminate with a first and a second nonwoven and an interposed prefabricated grid, wherein the grid at least with a fleece is connected before the laminate is stretched. Method according to claim 30, characterized in that that the constituents of the laminate are stretched together. Method according to claim 30, characterized in that that the constituents of the laminate are differently drawn. A method according to claim 30, 31 or 32, characterized characterized in that a film is laminated and stretched, wherein, in a bonding step, the film is heated to less than 80 ° C becomes. Method according to one of the preceding claims, characterized characterized in that the first nonwoven in conjunction with embossing points device and a higher one Nonwoven weight than the second nonwoven.