Base interlining, methods for their manufacture and application thereof

Abstract

The invention relates to a novel binder system and its use for bonding textile fabrics as well as products containing such bonded textile fabrics. The materials according to the invention are suitable for manufacturing base interlinings which may be used for manufacturing base interlinings for sarking, roofing and sealing membranes, particularly for manufacturing coated sarking, roofing and sealing membranes.

Claims

1. A textile fabric comprising: spunbonded textile fibers; and a binder to solidify the textile fibers into the textile fabric, wherein the binder is formed from a binder system comprising an aqueous dispersion of: starch; and emulsion polymers, wherein the aqueous dispersion has a viscosity of between 10 and 2200 mPa*s in accordance with DIN EN ISO 3219 and 23° C., and wherein the binder system has no ethylenically unsaturated carboxylic acids based on the weight of the binder system.

2. The textile fabric of claim 1, wherein the textile fabric has a heat dimensional stability of at most 1.6% in a longitudinal direction and at most 1.7% in a cross direction.

3. The textile fabric of claim 1, wherein the spunbonded textile fibers comprise both base and hot melt adhesive fibers wherein the proportion of the hot melt adhesive fibers in the textile fabric is less than 50 wt. % based on the weight of the textile fabric.

4. The textile fabric of claim 1, wherein the spunbonded textile fibers comprise one or more type of reinforcing fibers selected from the group consisting of aramid fibers, carbon fibers, glass fibers, mineral fibers, high-strength polyester fibers, high-strength polyamide fibers, and metal fibers.

5. The textile fabric of claim 1, wherein the starch comprises at least one vegetable starch selected from the group consisting of potatoes, manioc, arrowroot, batata, wheat, maize, rye, rice, barley, millet, oat, sorghum, chestnuts, acorns, beans, peas, and bananas.

6. The textile fabric of claim 1, wherein the starch comprises a mixture of amylose and amylopectin, and has a molecular weight M.sub.w between 5×10.sup.4 and 1×10.sup.7.

7. The textile fabric of claim 1, wherein the binder system further comprises one or more emulgators.

8. The textile fabric of claim 7, wherein the emulgators are selected from the group consisting of polyalkylene glycol, sulfonated parafinic hydrocarbons, alkyl sulphates, and alkaline metallic salts of fatty acids.

9. The textile fabric of claim 1, wherein the binder system further comprises one or more additives selected from the group consisting of a preservative, a stabilizer, an antioxidant, an antifoaming agent, a waterproofing agent, a UV stabilizer, a filler, and a pigment.

10. The textile fabric of claim 1, wherein the textile fabric has a weight per unit area of 20 g/m.sup.2 to 500 g/m.sup.2.

11. An article comprising: a spunbonded fiber-containing textile fabric; and a binder to solidify the textile fabric, wherein the binder is formed from a binder system comprising an aqueous dispersion of: starch; and emulsion polymers, wherein the aqueous dispersion has a viscosity of between 10 and 2200 mPa*s in accordance with DIN EN ISO 3219 and 23° C., and wherein the binder system has 3 wt. % or less of ethylenically unsaturated carboxylic acids based on the weight of the binder system.

12. The article of claim 11, wherein the article has a heat dimensional stability of at most 1.6% in a longitudinal direction and at most 1.7% in a cross direction.

13. The article of claim 11, wherein the article is selected from the group consisting of a sarking membrane, a roofing membrane, and a sealing membrane.

14. The article of claim 13, wherein the article is a bituminized roofing membrane.

15. The article of claim 11, wherein the article further comprises a granular material on at least one surface of the article.

16. A sarking, roofing, or coated sealing membrane reinforced by a base interlining, such interlining comprising a textile fabric which has been bonded with a binder system, the binder system comprising: 20 to 80 wt % (dry mass) of an aqueous dispersion of polymerisates based on conjugated aliphatic dienes and vinyl aromatic compounds, 10 to 90 wt % (dry mass) starch, and 0 to 10 wt % (dry mass) additives, wherein said fabric is a spunbonded nonwoven based on a partially aromatic or fully aromatic polyester, and wherein the wt % are based on the dry mass of the binder; and wherein the binder system has a viscosity of between 10 and 2200 mPa*s in accordance with DIN EN ISO 3219 and 23° C.

17. The sarking, roofing, or coated sealing reinforced by a base interlining according to claim 16, wherein the aqueous dispersion has 5 wt. % or less of ethylenically unsaturated carboxylic acids based on the weight of the binder system.

18. The textile fabric of claim 1, wherein the textile fabric is formaldehyde-free.

19. The sarking, roofing, or coated sealing reinforced by a base interlining of claim 16, wherein the textile fabric is formaldehyde-free.

20. The textile fabric of claim 7, wherein the emulgator is present in an amount from 1 to 5 parts by weight.

21. The textile fabric of claim 1, wherein the spunbonded fibers comprise melt-spinnable polyesters.

22. The textile fabric of claim 1, wherein the spunbonded fibers comprise at least 85 mol % polyethylene terephthalate.

23. The textile fabric of claim 1, wherein the spunbonded fibers comprise flame retardantly modified polyesters.

Description

EXAMPLES

(1) The following table 1 shows a comparison of the textile fabrics bonded with the binder system according to the invention against the respective single components of the binders.

(2) A spunbonded non-woven based on polyethylene terephthalate (PET-spunbond) with a weight per area unit of 180 g/m.sup.2 (Type JM33/180) is examined.

(3) Example 1 shows a standard binder system based on SBR and urea binder, example 2 shows a binder system based on urea and acrylate, example 3 shows a binder system according to the invention, example 4 shows a binder system based on starch and acrylate, example 5 shows a binder system based on starch. Typically, the liquor concentration is 15-40% (i.e. solid matter in liquor)

(4) TABLE-US-00001 Test no. 1 2 3 4 5 SBR-dispersion 90 40 urea resin 10 10 acrylate 90 40 dispersion starch 60 60 100 Set application [%] 20 20 20 20 20 (% weight of raw non-woven) Maximum [daN/5 cm] 56 59 57 51 46 longitudinal tensile force Maximum [daN/5 cm] 25 19 27 n.t. 31 longitudinal tensile force, hot Maximum cross [daN/5 cm] 47 48 45 36 36 tensile force Longitudinal TDS [%] 1.8 1.9 1.3 1.6 0.8 Cross TDS [%] −1.6 −1.8 −1.4 −1.7 −1.3 VW-Test [mg/kg FA] ~400 ~400 ~30 ~30 <10 Water suction [mm ] 80 72 72 59 66